Patent Publication Number: US-11027186-B2

Title: Protective headgear for sports participants, especially baseball fielders

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application is based on and claims priority to U.S. Provisional Patent Application 62/134,337, filed Mar. 17, 2015, and U.S. Provisional Patent Application 62/294,444, filed Feb. 12, 2016, the entire contents of each is incorporated by reference herein as if expressly set forth in its respective entirety herein. 
    
    
     TECHNICAL FIELD 
     The present invention relates to sports equipment and more particularly, relates to protective headgear that is designed to be worn by a baseball or softball fielder, especially a pitcher, to protect the fielder&#39;s head and face from being struck by a batted ball. 
     BACKGROUND 
     Baseball is known as America&#39;s pastime. Baseball is a bat-and-ball game played between two teams of nine players each who take turns batting and fielding. The offense attempts to score runs by hitting a ball thrown by the pitcher with a bat and moving counter-clockwise around a series of four bases, namely, first, second, third and home plate. A run is scored when a player advances around the bases and returns to home plate. 
     Fielders wear gloves to assist in catching a hit ball and typically wear soft brim caps as part of their uniforms. Batted balls can reach high speeds and therefore, there is a desire to provide the fielders with head and face protection from such batted balls. 
     SUMMARY 
     In one embodiment of the present invention, a protective headgear for a baseball or softball fielder (e.g., a pitcher thereof) is provided and includes a rigid outer protective shell that has a front portion, a first side portion, an opposing second side portion and a brim that extends outwardly from the front portion. The outer protective shell has a top opening and a rear opening that is defined between a first free end of the first side portion and a second free end of the second side portion. As a result, the protective headgear does not completely circumscribe the fielder&#39;s head. As described herein, the top opening allows the head to more easily “breathe” (allowing air and moisture transfer) and the rear opening allows the size (circumference) of the outer protective shell to be altered so as to ensure a proper snug fit is achieved regardless of the size of the fielder&#39;s head. 
     The protective headgear also includes an impact absorption material disposed along an inner surface of the outer protective shell and also an inner cap to be worn beneath the outer protective shell. In at least some of the embodiment, the headgear includes an impact absorption region that is formed as a multilayer structure formed of two or more energy absorbing materials. The inner cap is formed of a breathable material and can be in the form of a skull cap. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         FIG. 1  is a front and side perspective view of a protective headgear in accordance with another embodiment of the present invention; 
         FIG. 2  is a rear and side perspective view of the protective headgear of  FIG. 1 ; 
         FIG. 3  is a top plan view of the protective headgear of  FIG. 1 ; 
         FIG. 4  is a bottom plan view of the protective headgear of  FIG. 1 ; 
         FIG. 5  is a front elevation view of the protective headgear of  FIG. 1 ; 
         FIG. 6  is a front elevation view of the protective headgear of  FIG. 1  in use; 
         FIG. 7  is a front elevation view of the protective headgear of  FIG. 1  with optional eye shield; 
         FIG. 8  is right side elevation view of the protective headgear of  FIG. 1  with optional eye shield; 
         FIG. 9  is a front perspective view of an ocular shield for use with the protective headgear; 
         FIG. 10  is a front perspective view of an inner cap for use with the protective headgear; 
         FIG. 11  is a right side elevation view of the protective headgear of  FIG. 1  in use; 
         FIG. 12  is a left side elevation view of the protective headgear of  FIG. 1  in use; 
         FIG. 13  is a rear view of one ratchet mechanism for tightening the headgear; 
         FIG. 14A  illustrates an impact absorption layer according to a first embodiment; and 
         FIG. 14B  illustrates an impact absorption layer according to a second embodiment. 
     
    
    
     DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS 
       FIGS. 1-13  illustrate protective headgear  100  for use by a sports participant and more specifically, the protective headgear  100  is particularly constructed for use by a player of a sport, and more particularly, a baseball fielder, such as a baseball pitcher. The protective headgear  100  can also be thought of as being a protective helmet or cap. As described herein, the protective headgear  100  includes features to protect a player&#39;s head and face from being struck by a batted ball. 
     The protective headgear  100  includes a number of different parts that are assembled to form the complete product and more specifically, the protective headgear  100  includes an outer protective shell  110 . The outer protective shell  110  does not completely enclose the user&#39;s (player&#39;s) head but instead is designed such that it has an open top and an open rear. More specifically, the outer protective shell  110  has a front portion  120 , a first side portion  130 , an opposing second side portion  140  and a brim  150  that extends outwardly from the front portion  120 . The outer protective shell  110  has a top opening  160  and a rear opening  170  that is defined between a free end  132  of the first side portion  130  and a free end  142  of the second side portion  140 . 
     From a top view, the outer protective shell  110  generally has a U-shape in that it has an open rear as discussed above (i.e., the legs of the U are not continuous with one another). This U-shape allows for flex to accommodate varies head sizes and thus, serves as mechanism to ensure a proper fit with the user (fielder). The outer protective shell  110  has a top edge  111  that defines the top opening  160  and extends from the free end  132  of the first side portion  130  across the front portion  120  to the free end  142  of the second side portion  140 . The top edge  111  is also U-shaped. A bottom edge  113  of the outer protective shell  110  is defined by and extends across the first side portion  130 , the brim  150 , and the second side portion  140 . 
     As shown in the views of  FIGS. 1 and 5 , the top edge  111  in the front portion  120  can be slightly elevated relative to the top edge  111  of the first and second side portions  130 ,  140 . 
     The first side portion  130  can be thought of as being the left side earflap and the second side portion  140  can be thought of as being the right side earflap. When the protective headgear  100  is intended for use by a baseball pitcher, one of the first and second side portions  130 ,  140  can offer additional protection in view of the normal mechanics and motion of pitcher as the ball is released as shown and described herein. 
     It will also be appreciated that the first and second portions  130 ,  140  can, in one embodiment, be both modular and configurable so as to allow the first and second portions  130 ,  140  to be selected in view of certain parameters, such as the physical characteristics of the user (fielder). In this embodiment, the portions  130 ,  140  can thus be detachably coupled to the main (base) portion of the headgear. For example, a mechanical fit, such as a releasable snap-fit, can be provided between the portions  130 ,  140  and the main (base) portion to allow the user to select one portion  130  from amongst a set of portions  130  and one portion  140  from amongst a second of portion  140 . In addition, other parts, including a rear tensioning mechanism for tightening the headgear can also be constructed so as to be modular in nature. Various types of exemplary rear tensioning mechanism are described herein. 
     Generally, the pitcher winds up and delivery begins when the pitcher brings his arms together in front of his body (this is called coming set). After coming set, the pitcher takes a step toward home and delivers the pitch. Typically, pitchers from the set use a high leg kick, thus lunging toward home in pitching; a pitcher may instead release the ball more quickly by using the slide step, quickly stepping directly and immediately toward home and pitching. After releasing the ball, the pitcher assumes a fielding position. The natural body movement of the pitcher exposes one side of the head more than the other side based on whether the pitcher is a left-handed pitcher or a right-handed pitcher. More specifically, if the pitcher is a right-handed pitcher, the right side of the head is more exposed to a ball strike and similarly, if the pitcher is a left-handed pitcher, the left side of the head is more exposed. 
     As described below,  FIGS. 1-13  illustrate a protective headgear that has enhanced protection in that the temple protection can be asymmetric in that the temple protection (temple guard) on the dominant side of the player is enhanced, thereby resulting in different temple protection constructions. In another embodiment (not shown), the left side portion  130  and the right side portion  140  can be mirror images of one another in that the protective headgear in this embodiment offers symmetric temple protection (temple guards) and coverage over both ears. 
     More specifically, for purpose of illustration only,  FIGS. 1-8, 11 and 12  show the protective headgear  100  for a right-handed pitcher having enhanced temple protection on the right side (pitching side in this example); however, it will be appreciated that in the protective headgear  100  for a left-handed pitcher, the additional protection is merely reversed and is part of the left-side portion  130 . 
     For a right-handed pitcher, the left side (first side) portion  130  does not cover the left ear of the player but instead, the ear is left exposed as shown in  FIG. 6 . The left side portion  130  does include a first section  134  that provides temple protection and seats over the side of the head immediately in front of the left ear. The bottom edge of the left side portion  130  has a pronounced curved section  136  that accommodates the left ear and is disposed above the left ear during wearing of the protective headgear  100 . The curved section  136  tapers downward behind the left ear to the free end  132  of the left side portion  130 . 
     As mentioned, for a right-handed pitcher, the right side (second side) portion  140  includes enhanced protection in that the right side portion  140  hangs lower and substantially covers the right ear as shown in  FIG. 6 . An ear vent (opening)  141  is formed in the right side portion  140  to allow air to pass to the ear. As with the left side portion  130 , the right side portion  140  has a first section  144  that covers the temple and seats over the head immediately in front of the right ear. The right side portion  140  extends over and covers the area of the head immediately behind the ear. The right side portion  140  can include a second section  145  that is located below the ear vent  141 . 
     As shown in the figures, the right side portion  140  can be configured such that it also extends across an upper portion of the jaw. The illustrated ear vent  141  has a generally triangular or elongated shape and extends forward towards the face. However, it will be understood that the ear vent  141  can have any number of other shapes and can come in different sizes too. 
     The left side portion  130  can be thought of as being a left wing that extends rearwardly and the right side portion  140  can be thought of as being a right wing that extends rearwardly and is disposed across from the left side portion  130 . The left and right wings  130 ,  140  are flexible in nature to allow the protective shell  110  to be fitted to different sized heads and allow the closing and opening of the protective headgear  100  as described herein. In other words, the flexible nature of the two wings  130 ,  140  allows these two structures to be drawn toward one another to tighten the headgear  100  or they can further be separated apart to loosen the headgear  100 . 
     As shown in the figures, the top edge of the outer protective shell lies in at least two different planes with the top edge of the curved front portion  120  lying in a first plane above a second plane that contains at least a first portion of the first top edge of the first side wing  130  and at least a second portion of the second top edge of the second side wing  140 . The second plane intersects the first plane and passes through the curved front portion and wherein each of the first top edge of the first side wing  130 , including the first portion thereof, and the second top edge of the second side wing  140 , including the second portion thereof, extends in a direction from the respective rear edge towards the brim  150  which lies in a third plane that intersects the rear edges of the first and second side wings. At least the first side wing  130  has an ear portion formed along a bottom edge thereof for covering an ear of the player. The first top edge extending above the ear portion and further extending forward of the ear portion towards the brim  150  and rearward of the ear portion towards the rear edge. The brim  150  is disposed between the first top edge and the bottom edge of the first side wing  130 . 
     The outer protective shell  110  can be formed as a single piece (part) (integral structure) using traditional manufacturing techniques, such as a molding process. The outer protective shell  110  can be formed of any number of rigid materials that are suitable for the present application. In one exemplary embodiment, the outer protective shell  110  is formed of a composite material and more particularly, is formed of a carbon fiber/aramid composite for the purposed of dispensing impact energy across a field larger than the initial impact location. For example, the outer protective shell  110  can be made of a carbon fiber/aramid composite that has a thickness between about 1 mm and about 5 mm. 
     In one exemplary embodiment, the outer protective shell is formed of three layers of carbon fibers. For example, three layers of carbon weave cloth is combined with (embedded in) an epoxy resin to create the shell. The three layers can be laid out into an aluminum mold, are sandwiched against each other with an interior removable silicon “plug”, and then baked together so that the epoxy resin flows through the three layers of carbon fiber fabric. Once it cools, the epoxy resin becomes hard and the three layers of carbon fiber fabric act as shock barriers dispersing impact energy. 
     As described herein, the outer protective shell  110  can have a variable thickness (e.g., between 1.0 mm and 1.5 mm). Two impact zones are formed to have a thickness of 1.5 mm and the rest of the shell is formed to have a thickness of 1.0 mm. The two impact zones that are 1.5 mm thick are defined as the “front” and “side” impact zones as described herein and as defined in the NOSCAE test protocol. The increased localized thickness allows the headgear  100  to pass testing in these two impact zones and the rest of the shell  110  is thinner (1.0 mm) to keep weight to a minimum. 
     It will be appreciated that other materials can be used to form the outer protective shell  110  and in particular, the shell  110  can be formed as a non-composite structure. In some applications, the shell  110  can be formed of polycarbonate or other suitable material. The shell  110  can also be constructed such that it includes a bonded interlayer of a honeycomb or copolymer extruded material. In addition, the shell  110  can be constructed such that includes an insert molded EPS foam substructure chemically bonded (or otherwise bonded) to the outer shell  110 . 
     The protective headgear  100  includes an impact absorption structure (material)  200  that is disposed along and is secured to an inner surface of the outer protective shell  110 . The impact absorption structure (material)  200  can be formed as a single layer from a single material or can be formed of two or more layers that are formed of different materials as shown in the exemplary figures. The impact absorption structure  200  is intended to provide primary impact absorption. Each of the structures (materials) that form the headgear provide a level of impact absorption; however, the primary area of the impact absorption is the structure  200 . The bond between the shell  110  and the structure  200  (e.g., a honeycomb shaped structure as described herein) can be of a high strength to help engage the material of the structure  200  upon impact (e.g., help engage the cell structure of the honeycomb material upon impact). 
     In the illustrated embodiment, the impact absorption structure  200  is formed of two layers of material that offer the desired impact absorption properties. For purpose of illustration only, the figures show a solid block of impact absorption structure  200  and do not differentiate between the two layers that make up the structure  200 . Exemplary materials to form the two layered structure  200  are shown in  FIGS. 14A and 14B . For example, the impact absorption structure  200  is formed of a first layer  210  and a second layer  220 . The first layer  210  is disposed against the inner surface of the outer protective shell  110 , while the second layer  220  is disposed against the first layer  210 . The footprints of the first layer  210  and the second layer  220  can be the same or they can be slightly different. Typically, the footprints of the first layer  210  and the second layer  220  will be at least substantially the same. 
     For example, the first impact absorption layer  210  can be formed of a thermoplastic honeycomb comprised of a co-extruded polycarbonate (PC) for energy absorption. This structure provides uniform mechanical properties due to its circular cell structure, and offers high compressive strength in a low-density material, decreasing transmitted force and peak g-force acceleration. The honeycomb is an efficient energy absorber, which is vital to impact protection, and is highly breathable. Depending on cell size and polymer density compression strength (DIN 53421), the material has been tested and such testing has resulted in durability against 101 to 522 psi (0.7 to 3.6 MPa), compression strength increases with smaller cell size. The intercellular connection is achieved without the use of glues of adhesives, but rather by thermal welding, which increases visual and performance consistency. Individual tubes are co-extruded with an inner and outer layer, each comprised of a different polymer; the outer layer has a lower melting point than the inner layer. The tubes are stacked in a mold, which is then heated and pressurized melting the exterior layer of each tube providing a thermo-weld between all adjacent tubes. The tubes are then cross cut into sheets. The welded honeycomb sheets can be further processed into finished dimensions and shaped parts with milling, thermoforming, cutting, profiling, lamination, plating, etc. 
     In one exemplary embodiment, the first impact absorption layer  210  can have a thickness of between about 3 mm to about 15 mm (e.g., 10 mm thick). The footprint of the first impact absorption layer  210  can be the same or similar to the footprint of the outer protective shell  110 . Any number of means can be used to attach the first impact absorption layer  210  to the inner surface of the outer protective shell  110 . For example, an adhesive or other bonding agent (e.g., pressure sensitive adhesives) or mechanical fasteners can be used to attach the first impact absorption layer  210  to the inner surface of the outer protective shell  110 . Exemplary attachment means also include, RF welding, thermal bonding (e.g., heat activated epoxy film adhesive, etc.). 
     In another embodiment, the first impact absorption layer  210  can be an impact absorption material that can be provided in the form of a flexible plastic cushioning material layer that can provide a nearly linear force-deflection curve which allows for maximum comfort throughout the compression and shock cycle. The flexible plastic cushioning material layer can be formed of a plurality of molded flexible high polymer resin members comprising of inwardly directed indentations. The first layer  210  can have a thickness of about 13 mm. It will be understood that the first layer  210  can be formed to have other thicknesses; however, the first layer  210  will typically have a greater thickness than the second layer  220 . The first layer  210  is shown in  FIG. 14A . 
     The second layer  220  can be in the form of a protective padding product that can be in the form of a urethane foam material that is formed using breathable, anti-microbial, open or closed cell technology for the purpose of providing impact protection and comfort. The second layer  220  is shown in  FIG. 14B . The second layer  220  can have a thickness of between about 2 mm and about 9 mm. It will be understood that the second layer  220  can be formed to have other thicknesses; however, the second layer  220  will typically have a greater thickness than the first layer  210 . It will also be appreciated that the innermost layer of the impact absorbing material can have moisture wicking properties which are advantageous since the innermost layer contacts the hair and head of the user. For example, the innermost layer can be enclosed (encapsulated) within a moisture wicking anti-microbial fabric or the like or a thin layer of moisture wicking material can be applied to the inner surface of the innermost absorbing material. 
     As shown in the figures, the impact absorption structure  200  can cover most of the inner surface of the outer protective shell  110 ; however, the layer  200  can be eliminated from a portion of the right side portion  140  (for a right-handed pitcher). More specifically, the second section  145  of the right side portion  140  that covers and hangs below the ear can be free of the impact absorption structure  200 . The outer protective shell  110  still covers these areas and thus offers protection. The absence of structure  200  allows sound to travel directly to the ear without significant attenuation from the surrounding structures. 
       FIGS. 1-8, 11 and 12  show the protective headgear  100  incorporating the two layer impact absorption structure  200  that is described herein; however, a single layer of absorption material can equally be used or a structure with more than two layers can also be equally used so long as these structures are capable of performing the intended function (i.e., absorption of applied forces). 
     The protective headgear  100  includes a mechanism for adjusting the protective headgear  100  so that a secure fit is formed on the user&#39;s head.  FIG. 13  shows one mechanism  300 . The mechanism  300  is located at the rear of the protective headgear  100  and can be easily adjusted by the wearer of the protective headgear  100  so as to provide a secure, custom fit every time. By manipulating the mechanism  300 , the left side portion  130  and the right side portion  140  can be drawn together so as to tighten the headgear  100  around the head of the wearer. Conversely, if the mechanism  300  is manipulated in an opposite manner, the left side portion  130  and the right side portion  140  are separated from one another, thereby loosening the headgear  100  around the head of the wearer. The mechanism can thus be operated by a single hand. 
     In the illustrated embodiment of  FIG. 13 , the mechanism  300  is in the form of an adjustable ratchet closure system which has a first end  302  that is attached to the left side portion  130  and a second end  304  that is attached to the right side portion  140 . One or more actuators  310  of the mechanism  300  are configured to either drawn the ends  302 ,  304  toward one another or to cause separation between the ends  302 ,  304  and loosening of the protective headgear  100 . 
     The present figures set forth different types of adjustment mechanisms that can be used including some that pull the side portions  130 ,  140  together using a ratcheting mechanism or the like. For example,  FIGS. 1-8, 11 and 12  show an alternative mechanism  301  for adjusting the protective headgear  100  so that a secure fit is formed on the user&#39;s head. The mechanism  301  can be a ratchet based system or be another type and operates by having the wearer manipulate an actuator (e.g., a knob) to cause tightening or loosening of the mechanism  301  by pulling the sides  130 ,  140  together. 
     As shown in  FIG. 4 , the mechanism  301  can be connected to the sides  130 ,  140  by elongated elastic bands  303 ,  305 , respectively. These bands  303 ,  305  allows for movement of the mechanism  301  as the headgear is placed on or off the head and during wearing. 
     Alternatively, an elastic tension band (not shown) can be provided between the side portions  130 ,  140 . In yet another embodiment, the mechanism  300  can be of interchangeable type in that the free ends of the side portions  130 ,  140  can include a connector or the like for releasably connecting to the mechanism  300  to allow the wearer the option to swap out one mechanism for another mechanism. For example, a ratchet mechanism with complementary connectors at its ends can mate with the connectors at the free ends of the side portions  130 ,  140  and similarly, an elastic tension band with connectors at its ends can be mated to the connectors at the free ends of the side portions  130 ,  140 . This allows customization of the mechanism  300  that is used to tighten the headgear  100 . 
     Additional adjustment mechanisms can also be used with headgear  100 . 
     The protective headgear  100  is preferably intended to be worn with an inner cap  500  ( FIG. 10 ). The inner cap  500  is formed of a breathable material and is configured not to interfere with the use of the protective headgear  100 . For example, the inner cap  500  can be in the form of a skull cap formed of a breathable mesh. As is known, skull caps are stretchable so as to provide a tight fit when worn on the head. As a result, the protective headgear  100  can easily be worn over the skull cap  500 . Since the protective headgear  100  is open along its top, the top of the skull cap  500  is visible when the cap and headgear  100  are combined. It will be appreciated that the skull cap  500  can be formed to have one color and the protective headgear  100  can be formed to have another color. Indicia, such as team logos, can be placed on one or both of the skull cap  500  and the protective shell  110 . 
     Since the inner cap (skull cap)  500  is a separate part, it can be easily removed and cleaned or otherwise processed. This versatility also allows the appearance of the headgear to be slightly altered in that the color and/or indicia on the inner cap can be varied by simply switching the inner cap. 
     In one embodiment, the inner cap  500  and protective headgear  100  can be constructed such that the inner cap  500  is fixedly, yet releasably, attached (coupled) to the protective headgear  100 . In particular, the inner cap  500  can be attached to either the protective shell  110  or even the impact absorption structure  200 . Any number of different fastening techniques can be used to attach the inner cap  500  to the protective headgear  100 . For example, one or more fasteners (e.g., snaps, hook and loop material, etc.) can be used to attach the inner cap  500  to the protective headgear  100 . One half of the fastener pair is associated with the inner cap  500  and the other half of the fastener pair is associated with the headgear  100  (e.g., the protective shell  110  or the impact absorption structure  200 . 
     In another embodiment, a bead can be formed along the periphery of the inner cap  500  and can be received within a corresponding groove formed in the protective headgear  100  (e.g., the groove can be formed in either the shell  110  or the impact absorption structure  200 . To attach the inner cap  500  to the protective headgear  100 , the bead is inserted into the groove. To release the inner cap  500 , the bead is removed from the groove. 
     The attachment of the inner cap  500  is not permanent since it is directed to periodically remove the inner cap  500  for cleaning thereof. 
     It will also be appreciated that the headgear disclosed herein can be customized for a particular person using software that allows measurements to be taken of the user prior to manufacturing. For example, 3D head scanning technology can be used to ensure optimal player fit in that the shape and size of the various parts of the headgear can be made in view of this collected data (measurements). 
     The protective headgear  100  can include a number of optional accessories.  FIGS. 7-9  show an ocular shield  400 . The ocular shield  400  can come in any number of different shapes and sizes. For example, the ocular shield  400  can come in a half shield format as shown in the aforementioned figures or can come in a full shield format (not shown) or other size. In the illustrated half shield format, the ocular shield  400  covers the eyes and the bottom edge extends across the nose. The ocular shield  400  is formed of a material that is suitable for use an optic element and thus, is formed of an optics grade material. For example, the ocular shield  400  can be formed of high strength polycarbonate and can have a thickness of between about 2 mm to about 3 mm in one embodiment. 
     The ocular shield  400  has an arcuate (curved) shape that terminates in a first end  402  and an opposite second end  404 . The first end  402  is attached to the first (left) side portion  130 , while the second end  404  is attached to the second (right) side portion  140 . Any number of different techniques can be used to couple and securely attach the ends  402 ,  404  to the respective first and second side portions  130 ,  140 . For example, the attachment can be of a detachable type or can be permanent in nature. To attach the ends  402 ,  404 , fasteners  410  or the like can be used. In addition, a mechanical coupling can be used to attach the ocular shield  400  to the outer protective shell. For example, one of the outer protective shell  110  and the ocular shield  400  can include a protrusion and the other of the outer protective shell  110  and the ocular shield  400  can include a slot that receives the protrusion. The slot can include a locking portion into which the protrusion slides to thereby lock and attach the ocular shield  400  to the shell  110 . 
     In addition, as shown in  FIG. 9 , the ocular shield  400  can also include a top lip or flange  415  that includes openings  412  that can mate with complementary features, such as locking protrusions, that are part of the protective shell  110 , such as along the underside of the brim. This provides additional attachment points between the ocular shield  400  and the protective shell  110  beyond attachment to the side portions (temple portions)  130 ,  140  of the protective headgear  100 . 
     In one embodiment, the protective headgear  100  includes an outer protective shell  110  and the impact absorption structure  200  which can be in the form of a multi-layer structure as described herein. 
     As mentioned previously, the outer protective shell  110  can have a variable wall thickness and more specifically, the shell construction is optimized to provide additional protection where the wearer is most vulnerable and is thinner in other less vulnerable regions to minimize weight. In particular, the areas of increased vulnerability are the forehead; the temple(s) region; and the side(s) of the head. In  FIGS. 1-8 , the regions of increased thickness, identified at  612 , are noticeable and appear visually as slight bulges along the shell surface. The transition from one increased thickness region  612  to an adjacent area or region of reduced thickness, identified at  614 , is marked by a sloped surface  615 . The sloped surface  615  blends the two regions  612 ,  614  together in an aesthetically pleasing manner. The region of increased thickness  612  can be located on both sides of the outer protective shell  110  or can be located only on the side that includes the ear protection and marks the side that faces the direction at which the ball is thrown (e.g., the pitcher&#39;s mound). 
     By varying the thickness of the outer protective shell  110  in a localized manner, the shell  110  provides increased protection in the vulnerable regions, while the less vulnerable areas have reduced thickness, which provides an overall weight reduction in the protective headgear  600 . 
     The outer protective shell  110  can be formed of the same materials as the outer protective shell  110  and therefore, can be formed of a composite material as discussed herein. As shown in  FIG. 8 , the top edge of the outer protective shell  110  lies in at least two different planes with the top edge of the curved front portion lying in a first plane (P 1 ) above a second plane (P 2 ) that contains at least a first portion of the first top edge of the first side wing and at least a second portion of the second top edge of the second side wing. The second plane (P 2 ) intersects the first plane (P 1 ) and passes through the curved front portion above the brim. Each of the first top edge of the first side wing, including the first portion thereof, and the second top edge of the second side wing, including the second portion thereof, extends in a direction from the respective first and second rear edges towards the brim which lies in a third plane (P 3 ) that intersects the first and second rear edges of the first and second side wings. 
     As discussed herein, the impact absorption structure  200  can be formed of the first layer  210  and the second layer  220 . The first layer  210  is adjacent the outer protective shell  110 , while the second layer  220  is disposed against the first layer  210  and is in contact with the head of the wearer. 
     As mentioned herein, the first layer  210  can be in the form of a copolymer honeycomb matrix impact absorption layer. The lightweight copolymer honeycomb matrix acts as a “crumple zone,” providing the second layer of impact absorption defense. 
     The second layer  220  can be in the form of a non-Newtonian foam liner. Any number of different non-Newtonian foam materials can be used so long as they are suitable for the intended application described herein. Suitable materials for the second layer  220  are described herein and include urethane foams. 
     The second layer  220  can be in the form of a single layer or the second layer  220  can itself be comprised of multiple layers (e.g., a laminate formed of multiple foam layers. More specifically, the second layer  220  can be a multi-layer non-Newtonian foam liner. For example, the second layer  220  can be formed of two or more discrete layers of non-Newtonian foam with each layer having different material characteristics. In one exemplary embodiment, the second layer  220  comprises three discrete foam layers that are bonded to one another and have varying densities. In particular, the densities of the three layers progressively increase in a direction from the inside of the helmet toward the outside. In other words, the density of the innermost foam layer that contact the wear&#39;s head has the lowest density, while the outermost foam layer that is in contact with the first layer  210  has the highest density (and the intermediate foam layer has a density between these two densities). 
     The multilayer foam liner (second layer  220 ) utilizes varying densities, which have been optimized for fit and comfort. The contouring non-Newtonian foam instantly dissipates force upon impact to disperse the energy, especially for high-speed impacts. 
     In one embodiment, the multilayer foam liner comprises a three layer foam (e.g., urethane foam) laminate. In other words, the three layer foam can be formed of the same material, such as urethane. A selected first foam layer has a first thickness and a first density and is laminated to a second foam layer that has a second thickness and a second density. The first and second thicknesses can be the same or can be different and in one example, each of the first and second thicknesses can be about 3 mm and the first density is greater than the second density. A selected third foam layer has a third thickness and a third density and is laminated to the second foam layer. Prior to lamination, the third foam layer can be skived so as to impart a pattern on one side of the foam layer and the skiving step results in the third foam layer having a variable thickness. For example, the third foam layer can have a thickness that is less than the first and second thicknesses (e.g., a variable thickness from 0.5 mm to about 2.5 mm). This third foam layer preferably has a different density than the other layers so as to act as a comfort foam due to its positioning next to and in contact with the wearer&#39;s head. 
     As will be appreciated from the foregoing discussion, the outer protective shell  100  helps to spread the energy (from an applied force) across the whole of the head, while the impact absorption structure  200  acts as both a crumple zone and compresses (foam) and absorbs the impact energy. Further, the multi-layer foam laminate adds to impact protection by slowing down the speed of the impacted object at different rates of times due to the different density foams. 
     While the protective headgear is described herein as being for use in the sport of baseball, the headgear can be in the sport of softball and also can equally be used in other sports in which head protection is desired. 
     The protective headgear described herein not only provides the desired protection but also provides a number of other advantages. More specifically, the protective headgear  100  is based on a proven cap form factor and is designed to provide good ventilation and a secure fit. The protective headgear is configurable with options to protect vulnerable temples and the face of the wearer. The various constructions described and illustrated herein, provide temple protection on both sides and frontal protection with the rigid brim. In one embodiment, full ear protection is provided for the pitching side. Facial protection is provided with the optional ocular shield. 
     As discussed herein, many of the features and the actual construction of the headgear can be customized for a particular user. For example, 3D anatomical scanning can be performed, the temple and ear protection described herein can be customized and there also customization options for the eye, nose, and full face protection. Thus, the construction of the headgear can be part of a computer implemented process in which certain anatomical data is first collected by a computer system and then software, such as a 3D modeling program, can be used to create a graphic representation of the user&#39;s head. From this graphic representation, the various components of the present headgear can be modeled and then formed so as to provide the user with a custom fit headgear. 
     In one exemplary embodiment, the protective headgear  600  has the following specifications: 
     Thickness: ˜0.7″ 
     Weight: Between about 10 and 12 ounces based on head size. 
     Protection: Laboratory testing shows that the Half Cap passes the National Operating Committee on Standards for Athletic Equipment (NOCSAE) standard at a minimum of 85 mph. 
     While the invention has been described in connection with certain embodiments thereof, the invention is capable of being practiced in other forms and using other materials and structures. Accordingly, the invention is defined by the recitations in the claims appended hereto and equivalents thereof.