Patent Publication Number: US-6986167-B1

Title: Protective headgear

Description:
RELATED APPLICATIONS 
   This application is a continuation-in-part application of Application Ser. Nos. 29/191,725, Patent D, 499,847, 29/191,726, Patent D 500,894, and 29/191,727, Patent D 500,179 all of which were filed on Oct. 14, 2003. The entire disclosures of these applications are expressly incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to protective headgear. More specifically, the present invention relates to protective headgear having cushioned, multi-layer ear guards and a head support configuration that securely and comfortably cradles a wearer&#39;s head. 
   2. Related Art 
   In various sports, such as wrestling, it is necessary to protect a participant&#39;s head and ears from injury. Various headgear designs have been developed to achieve this goal, most of which include a pair of ear guards that fit about the wrestler&#39;s ear, interconnected by a plurality of adjustable straps for securing the headgear to the wrestler&#39;s head. Further, various cushioning systems have been developed and incorporated with such ear guards to provide added comfort for the wearer. However, a particular problem with existing cushioning systems is that such systems do not adequately provide protection from shock while retaining a comfortable fit during use. Further, many existing ear guards do not provide adequate ventilation for the wearer. 
   Additionally, present headgear designs include a plurality of straps interconnecting the ear guards of the headgear. Frequently, such straps include buckles or other attachment means that must be individually adjusted and tightened to provide a suitable fit for the wearer, thereby requiring time and effort on the part of the wearer prior to a sporting event. Moreover, existing headgear designs are prone to slippage, wherein one or more of the straps shift position during a sporting event, thereby leading to an uncomfortable and potentially dangerous situation. Indeed, most headgear straps are cumbersome to operate and wear, and do not conform to or “cradle” the shape of the wearer&#39;s head to provide a reliable and comfortable fit. Additionally, the straps of existing headgear do not provide sufficient cushioning for the wearer&#39;s head. 
   Accordingly, what is desired, but has heretofore not been provided, is protective headgear wherein sufficient cushioning is provided, and wherein a comfortable and reliable fit is provided about the head of the wearer. 
   SUMMARY OF THE INVENTION 
   The present invention relates to protective headgear. The headgear includes a pair of ear guards joined by a head support that cradles the top of the wearer&#39;s head to provide a comfortable and stable fit during use. The head support includes first and second lateral straps connected at ends thereof to the ear guards, and a transverse strap interconnecting the first and second lateral straps. The transverse strap includes a central body with frontward and rearward legs attached at ends thereof to the first and second lateral straps. The transverse and lateral straps can be adjusted to provide a desired fit about and to “cradle” the head of the wearer. An adjustable chin strap is attached at ends to the ear guards, and can be selectively adjusted to provide a desired fit about the chin of the wearer. 
   The present invention also relates to a protective headgear having one or more head straps that include a cushioning material within the straps for cushioning the head of a wearer during use. The cushioning material is positioned between the layers of material forming the strap. The cushioned head straps absorb shock occurring during a sporting event, and provide a comfortable fit. 
   The present invention further provides an ear guard that cushions the head of the wearer when the ear guard is worn. The ear guard includes a shell portion surrounded by an outer wall and an annular inner wall. The shell portion includes a plurality of slots for the connection of head straps thereto. The outer wall forms the exterior of the ear guard, and can include a nylon laminate material, and is joined along the perimeter thereof to the inner wall. A landing pad surrounds the perimeter of the shell. The inner wall and outer wall retain the shell portion therebetween, and the inner wall includes a compressible material that aligns with the landing pad and provides cushioning for the head of the wearer. 
   The present invention also provides an ear guard having plural ventilation areas for providing ventilation and transmitting sound to a wearer&#39;s ears. The ear guard includes an outer wall, and an annular wall joined at the perimeter thereof to the outer wall, and a shell positioned between the inner and outer walls. The ventilation areas, each of which include a plurality of apertures, are formed in the shell. The ventilation areas are on raised portions of the shell and protrude through apertures in the outer wall. The outer wall can be formed of a plastic material, and a nylon laminate can be provided on the outer surface of the outer wall. A landing pad surrounds the perimeter of the shell. The inner wall includes a cushioning material that aligns with the landing pad and cushions the head of a wearer. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other important objects and features of the invention will be apparent from the following Detailed Description of the Invention taken in connection with the accompanying drawings in which: 
       FIG. 1  is front view of the protective headgear of the present invention. 
       FIG. 2  is a side view of the protective headgear shown in FIG.  1 . 
       FIG. 3  is a rear view of the protective headgear shown in FIG.  1 . 
       FIG. 4  is a top view of the protective headgear shown in FIG.  1 . 
       FIG. 5  is a bottom view of the protective headgear shown in FIG.  1 . 
       FIG. 6  is a cross-sectional view showing the ear guard of the present invention, taken along the line  6 — 6  of FIG.  2 . 
       FIG. 7  is a cross-sectional view of one of the lateral straps of the protective headgear of the present invention, taken along the line  7 — 7  of FIG.  3 . 
       FIG. 8  is an exploded perspective view of the ear guard of the present invention. 
       FIG. 9  is a side view showing another ear guard according to the present invention. 
       FIGS. 10   a-   10   b  are end views of the ear guard shown in FIG.  9 . 
       FIG. 11  is an exploded perspective view of the ear guard of FIG.  9 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention relates to protective headgear having cushioned, multi-layer ear guards and a head support connecting the ear guards and cradling a wearer&#39;s head to provide a comfortable and stable fit during use. The head support comprises first and second lateral straps interconnecting the ear guards, and a transverse strap interconnecting the lateral straps. The transverse strap includes a central portion and legs on opposite sides of the central portion which interconnect with the lateral straps. A head strap construction is also provided, and includes a cushioning material disposed between layers of material forming the strap. 
   The ear guards of the present invention include an outer wall and an annular inner wall. A shell portion is positioned between the inner and outer walls, and includes a plurality of slots for attachment with head straps. A landing pad is attached about the perimeter of the shell. The inner wall is joined at a perimeter thereof to the outer wall, and includes a compressible material that aligns with the landing pad and provides cushioning for the head of the wearer. In one embodiment, the ear guards of the present invention include ventilation areas formed on raised portions of the shell. The outer wall includes apertures which accommodate the raised portions of the shell. 
     FIG. 1  is front view of the protective headgear of the present invention, indicated generally at 10. The headgear  10  comprises a head support  20  interconnected with ear guards  30 . The head support  20  comprises a first lateral strap  22  and a second lateral strap  28 . Ends  29  of the second lateral strap  28  are threaded through slots in the ear guards  30 , and are releasably attached (e.g., via hook-and-loop fasteners) back onto the body of the second lateral strap  28 , so that the overall length of the second lateral strap  28  can be adjusted as desired. The construction of the first lateral strap  22  is similar to that of the second lateral strap  28 . Optionally, the ends of the straps could otherwise interconnect with the ear guards  30  such as by extending the ends of the straps through apertures in the ear guards and stitching the ends back onto the straps, or in any other manner known in the art. 
   A transverse strap  24  interconnects the first lateral strap  22  and the second lateral strap  28 . The transverse strap  24  includes a central portion  23  and forward legs  25   a ,  25   b  and rear legs  26   a ,  26   b , which interconnect with the first and second lateral straps, respectively. As shown in  FIG. 1 , rear legs  26   a ,  26   b  are releasably attached to the second lateral strap  28  by ends  27 , which are threaded through slots in the second lateral strap  28  and releasably attached back onto the legs  26   a ,  26   b . Optionally, the legs  27  could be stitched to the legs  26   a ,  26   b  or permanently attached thereto. If desired, the forward legs  25   a ,  25   b  could also be releasably attached to the first lateral strap  22 , and the rear legs  26   a ,  26   b  could be fixedly or releaseably attached to the second lateral strap  28 . 
   If desired, the head support  20  could be fabricated in a unitary construction, wherein the first lateral strap  22 , the second lateral strap  28 , the transverse strap  24 , the forward legs  25   a ,  25   b , and the rear legs  26   a ,  26   b  are formed together. Additionally, the head support  20  can be formed without the forward and rear legs  25   a ,  25   b ,  26   a , and  26   b , wherein a single transverse strap is attached at ends between the first lateral strap  22  and the second lateral strap  28 , or the transverse strap could include one set of legs. 
   Important, the head support  20  cradles the head of a wearer to provide a secure and comfortable fit while wearing the headgear  10 . The head support  20  can be made of any suitable, flexible material, such as a synthetic woven material. An adjustable chin strap  40  is provided and attached to the ear guards  30  by rings  42 . The chin strap  40  can be attached to the ear guards  30  in any desired, known manner, such as by extending ends of the strap  40  through rings  42  and fastening the ends back onto the strap  40  with a hook-and-loop fastening system. The chin strap  40  can be adjusted to accommodate any desired fit. 
   The ear guards  30  are formed of a multi-layer construction and provide protection for a wearer&#39;s ears while maintaining a comfortable fit. Each of the ear guards  30  comprises an outer wall  32  having one or more apertures  34  for allowing the transmission of sound to the wearer&#39;s ear and for providing ventilation for the ear guards  30 . An annular inner wall  36  contacts the head of the wearer around the wearer&#39;s ear, and is preferably formed from a smooth, compliant material, such as Neoprene. The inner wall  36  is joined along the perimeter thereof to the outer wall  32 . Gaps are provided between the inner wall  36  and outer wall  32  are provided to allow for the engagement of head straps with the ear guards  30 . The inner wall  36  includes a central aperture  38  for receiving a wearer&#39;s ear. The cavity within the ear guard  30  provides sufficient room for the ear to be comfortably housed and protected thereby. 
     FIG. 2  is a side view of the protective headgear  10  shown in FIG.  1 . The first lateral strap  22  extends from the ear guard  30 , and rests near the forehead of a wearer&#39;s head. The second lateral strap  28  extends from the ear guard  30 , and rests against the back of the wearer&#39;s head. The transverse strap  24  is interconnected between the first and second lateral straps  22  and  28  by forward legs  25   a  (not shown) and  25   b , and rear legs  26   a  (not shown) and  26   b . Aperture  34  of the ear guard  30  can be covered with a mesh-like material, as shown, that allows sound and air to be transmitted therethrough. Alternatively, the aperture  34  could be left open. 
     FIG. 3  is a rear view of the protective headgear  10  shown in FIG.  1 . The forward legs  25   a ,  25   b  are attached to the first lateral strap  22 , and connect the first lateral strap  22  to the transverse strap  24 . The rearward legs  26   a ,  26   b  attach the transverse strap  24  to the second lateral strap  28  via ends  27  threaded through apertures  29  of the second lateral strap  28  and attached back on the rearward legs  26   a ,  26   b  (e.g., by hook-and-loop type fastener). Ends  33  of the first lateral strap  22  are threaded through slots in the ear guard  30 , and are releasably attached back on the first lateral strap  22  by hook-and-loop type fasteners. Optionally, the ends  33  could be stitched or permanently attached to the first lateral strap  22 . The chin strap  40  attaches at ends to the ear guards  30  by rings  42 . Straps  41 , interconnected with the car guards  30 , support the rings  42 . 
     FIGS. 4 and 5  are top and bottom views, respectively, of the headgear  10  shown in FIG.  1 . As can be seen in  FIG. 4 , the head support  20  interconnects the ear guards  30 , and provides a comfortable fit about the head of a wearer. The first lateral strap  22  and second lateral strap  28  are adjustable with relation to the ear guards  30 , and the legs  26   a ,  26   b  are adjustable with relation to the second lateral strap  28 . As can be seen in  FIG. 5 , such adjustment is provided by ends  33  of first lateral strap  22  can be releasably attachable by hook-and-loop fasteners, or otherwise attached. The chin strap  40  is also adjustable to accommodate a desired fit, and is connected between the ear guards  30 . 
     FIG. 6  is a cross-sectional view showing the ear guard  30  of the present invention, taken along the line  6 — 6  of FIG.  2 . The ear guard  30  is lightweight, durable, and provides sufficient cushioning for the wearer&#39;s head to remain comfortable during use yet provide protection against injury. The outer wall  32  comprises a compressed, flexible material, such as ethylene vinyl acetate (EVA) that is optionally laminated with a nylon material to provide a smooth outer surface. A rigid inner shell  54  protects the wearer&#39;s ear, provides shape for the ear guard  30 , and defines a cavity  57  for receiving a wearer&#39;s ear. The shell  54  preferably comprises a rigid polypropylene material, but could be manufactured from other suitable materials. A generally annular landing pad  56  formed of a compressible material such as EVA is attached to the perimeter of the shell  54 . 
   An inner wall  36  is attached, such as by stitching, to the edges of the outer wall  32 . Other methods of attachment of the components of the present invention, such as sonic welding, etc., are considered within the scope of the invention. The inner wall  36  can include an annular compressible or “memory” layer  50 , which is retained in position by an annular backing. The memory layer  50  aligns with the landing pad  56 . The memory layer  50  could be manufactured from a compressible foam material, such as KINETO foam material manufactured by Wind Enterprises, Inc. The memory layer  50  provides cushioning for the wearer&#39;s head while absorbing shocks occurring during a sporting event. Each of the layers of the ear guard  30  can be formed from readily-available materials to provide an ear guard that is lightweight yet sufficiently rigid to protect a wearer&#39;s ears from injury, while providing a cushioned fit that is comfortable to wear. 
     FIG. 7  is a cross-sectional view of the first lateral strap  22  of the protective headgear of the present invention, taken along the line  7 — 7  of FIG.  3 . The strap  22  can include a compressible material  64  positioned between walls  60  and  62  to protect the wearer against injury. The compliant material  64  could be the same material used for memory layer  50  of the ear guards  30  (e.g., KINETO foam material), or any other suitable material capable of absorbing shock while remaining relatively flexible. The walls  60  and  62  are joined at edges in any desired manner, such as by stitching. A welt  66  can be used to cover this junction between the walls  60  and  62 , and stitched into place. 
     FIG. 8  is an exploded view showing the components of the ear guard  30  of the present invention. The ear guard  30  could be crescent-shaped, but any other desired shape can be utilized without departing from the spirit or scope of the present invention. The shell  54  includes a plurality of slots  43   a ,  43   b , and  43   c  for engagement with head straps. Aperture  43   c  is positioned for interconnection with a chin strap. It can receive a loop  41  of material to which a ring  42  is connected. The ring  42  receives an end of the adjustable chin strap  40 . A plurality of apertures  44  are provided on the shell  54  to allow air and sound to be transmitted through the shell  54 . This allows a wearer to hear while wearing the headgear of the present invention, and also provides ventilation. 
   Apertures  44  align with the aperture  34  of outer wall  32 . As mentioned earlier, the aperture  34  could be covered with a mesh-like material capable of transmitting air and sound, or left open. The memory layer  50  aligns with the landing pad  56 , and the memory layer  50 , the landing pad  56 , and the shell  54  are partially enclosed by the outer wall  32  and the inner wall  36 . The outer layer  32  includes a plurality of slits  37   a ,  37   b , and  37   c  along the seam formed at the union of outer layer  32  and inner layer  36  to allow head and chin straps to be inserted therethrough for engagement with apertures  43   a ,  43   b , and  43   c  of the shell  54 . 
     FIG. 9  is a side view showing another embodiment of the ear guard of the present invention, indicated generally at 300. Again, the ear guard  300  comprises a perimeter area  320  that includes a plurality of slots  350  for allowing attachment to straps  360 . A dome-shaped central portion  370  is provided, and includes ventilation areas  340  disposed generally radially from the center of the dome-shaped central portion  370 , and positioned on elevated surfaces of the shell. Each of the ventilation areas includes a plurality of apertures for allowing air and sound to transmit through the ear guard  300 . This ear guard  300  is formed of a multi-layer construction similar to ear guard  30 , discussed earlier. 
     FIGS. 10   a  and  10   b  are side views of the ear guard  300  shown in FIG.  9 . As can be seen, the ventilation areas  340  protrude through apertures in the dome-shaped central portion  370 . 
     FIG. 11  is an exploded perspective view showing the ear guard  300  of FIG.  9 . An outer wall  400  is provided, and includes a plurality of apertures  405 , which are disposed generally radially from the center of the outer wall  400 . Outer wall  400  is preferably manufactured from a compressed material, such as EVA or other suitable material, and can be covered with a nylon laminate to provide a smooth outer surface. A shell  410  provides a generally dome-shaped cavity for receiving the ear of a wearer, and includes raised ventilation areas  340  disposed generally radially about the center of the shell  410 . Each of the ventilation areas  340  includes a plurality of apertures for allowing the transmission of sound and air. Each of the ventilation areas  340  align with the apertures  405  of the outer wall  400 , so that the ventilation areas  340  protrude through the outer wall  400 . The shell  410  could be manufactured from a suitably rigid material, such as polypropylene, and includes a plurality of slots  380  for receiving the ends of head and chin straps. A landing pad  420  is attached to the perimeter of the shell  410 , and can be manufactured from compressed EVA or other similar material. 
   An inner wall  440 , preferably manufactured from neoprene or other similar material, is attached at the perimeter thereof by any suitable mean, such as by stitching, to the outer wall  400 . A cushion layer  430 , manufactured from a foam material aligns with the landing pad  420 , and is preferably included in the inner wall  440 . The construction and stitching of the inner wall  440 , the cushion layer  430 , the interior wall, and the landing pad  420  can be identical to the ear guard  30  described earlier. 
   Having thus described the invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit and scope thereof. What is desired to be protected by Letters Patent is set forth in the appended claims.