Patent Publication Number: US-8973171-B2

Title: Form-fitting protective headwear

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part of U.S. patent application Ser. No. 13/531,065, filed on Jun. 22, 2012, which is a continuation of U.S. patent application Ser. No. 13/362,834, filed on Jan. 31, 2012, which is a continuation-in-part of U.S. patent application Ser. No. 13/231,434, filed on Sep. 13, 2011, and which also claims priority to U.S. Provisional Patent Application No. 61/580,949, filed on Dec. 28, 2011, and U.S. Provisional Patent Application No. 61/584,896, filed on Jan. 10, 2012, all of which are incorporated herein by reference in their entireties. 
    
    
     BACKGROUND 
     1. Field 
     The present application relates to headwear. More specifically, the present application is directed to a form-fitting protective headwear and a method of manufacturing the form-fitting protective headwear. 
     2. Brief Discussion of Related Art 
     Protective headwear can include hardhats, bumphats, helmets, headgear and other types of protective headwear, which provide a protective function (e.g., various levels of protection) against head injuries resulting from various impacts to the head associated with accidents and/or intentional acts of others. Protective headwear can be used for various activities ranging from military/security applications, to industrial applications, to sports activities, through to leisure activities. The different applications and activities can require different levels of protection and accordingly different headwear. 
     In many circumstances, head injuries can be prevented by using protective headwear. While job-related, sports-related, security-related as well as leisure-related head injuries can be very serious and even life threatening, some people (e.g., especially young people) may prefer not to wear headwear for various reasons, including aesthetics (e.g., user&#39;s look and feel), comfort (e.g., user feels uncomfortable wearing headwear), application/activity-specific fit (e.g., headwear for use in one application/activity does not accord well with use for another application/activity), and expense (e.g., headwear for different activities is too expensive). Other reasons may exist, such as experience level (e.g., user feels too experienced to wear headwear). 
     The foregoing and other reasons or factors can cause some people to go without protective headwear and increase the potential for serious head injuries. Accordingly, protective headwear should aim to not only to provide a protective function but should also aim to provide an inexpensive, yet aesthetic, comfortable and secure fit such that users would desire to wear the protective headwear. While providing the protective function, existing protective headwear frequently misses the mark and does not provide an aesthetic, comfortable and application-specific fit that is inexpensive, causing people to go without protective headwear and increasing the potential for serious head injuries. 
     Fit and positioning of headwear are essential to effectiveness at reducing head injury. In this regard, stretchable headwear (e.g., ski hats) offers the form-factor and the convenience of a precise fit and positioning for various head sizes. Stretchable headwear can be made of a various fabrics, including manmade/synthetic materials, natural materials, or blended combinations thereof. Accordingly, stretchable headwear can provide an inexpensive form-factor and esthetic quality, which can result in increased desirability. Desirability cannot be underestimated in people&#39;s desire or lack thereof for wearing protective headwear. 
     However, the method of placing protective materials (protective function) into stretchable headwear while maintaining its aesthetic quality have been problematic. On the one hand, hard layered plastics provide great protection but are too bulky and thus ruin the aesthetics, decreasing desirability and increasing the potential for serious head injuries. On the other hand, simple padding provides great esthetics but does not provide sufficient protection, decreasing the protective function and increasing the potential for serious head injuries. Furthermore, the manufacture of the stretchable headwear that incorporates sufficient protective function has met with challenges. 
     It is therefore desirable to provide a combination of sufficient protective function and aesthetics such that people will more readily wear protective headwear during their engagement in different activities and reduce the potential for serious injuries. 
     SUMMARY 
     In accordance with an embodiment, a protective headwear is disclosed. The protective headwear includes a body, a pocket band, a cuff and a plurality of protective inserts. 
     The body has an opening and a crown, and is configured to fit a head of a person. 
     The pocket band extends about the opening to an interior of the body and partially toward the crown. Moreover, the pocket band is free floating with respect to the body and configured to fit the head of the person. The pocket band also includes a plurality of pockets disposed about a base stitching that secures the pocket band to the body. 
     The cuff extends about the body and away from the crown. Moreover, the cuff incorporates a cuff element. The cuff element can be made of foam rubber, or other similar material. 
     The plurality of protective inserts configured to be received into the plurality of pockets to provide a protective function to the head of the person. Moreover, the protective inserts are disposed adjacently to one another about the pocket band and extend from the base stitching of the pocket band to the crown of the body. 
     These and other purposes, goals and advantages of the present application will become apparent from the following detailed description of example embodiments read in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Some embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings in which: 
         FIG. 1  illustrates a person wearing an example protective headwear in accordance with a first embodiment; 
         FIG. 2  illustrates the construction of the example protective headwear of  FIG. 1 ; 
         FIG. 3  illustrates the construction of an example pocket in the pocket band of the protective headwear of  FIG. 2 ; 
         FIG. 4  illustrates the construction of an example protective insert in accordance with a first embodiment for insertion into the pocket band of  FIGS. 2 and 12 ; 
         FIG. 5  illustrates the construction of an example protective insert in accordance with a second embodiment for insertion into the pocket band of  FIGS. 2 and 12 ; 
         FIG. 6  illustrates the construction of an example protective insert in accordance with a third embodiment for insertion into the pocket band of  FIGS. 2 and 12 ; 
         FIG. 7  illustrates a cross-section of the example protective headwear in accordance with the first embodiment of  FIG. 1 ; 
         FIG. 8  illustrates a cross-section of the example protective headwear of  FIG. 7  with the protective insert disposed in the pocket; 
         FIG. 9  illustrates a person wearing the protective headwear of  FIG. 1  cutaway to reveal the protective insert in relation to the body and the cuff of the protective headwear; 
         FIG. 10  illustrates a cross-section of the protective insert in accordance with the first embodiment of  FIG. 4  showing an example protective function in response to an impact; 
         FIG. 11  illustrates a person wearing an example protective headwear in accordance with a second embodiment; 
         FIG. 12  illustrates the construction of the example protective headwear of  FIG. 11 ; 
         FIG. 13  illustrates a cross-section of the example protective headwear of  FIG. 11 ; 
         FIG. 14  illustrates a cross-section of the example protective headwear of  FIG. 13  with the protective insert disposed in the pocket; 
         FIG. 15  illustrates construction of an example tube made of stretchable or elastic woven fabric (thread), which can be formed into the protective headwear of the first embodiment or the second embodiment of  FIGS. 1 and 11 , respectively; 
         FIG. 16  illustrates a first folding operation shown along a cross-section of the example tube of  FIG. 15 ; 
         FIG. 17  illustrates a second folding operation and a stitching operation shown along the cross-section of the example tube of  FIG. 15  to form the body, cuff  106  and pocket band of  FIG. 1 ; 
         FIG. 18  illustrates an example method of manufacturing the example protective headwear of  FIG. 11 ; 
         FIG. 19  illustrates a third optional folding operation shown along the cross-section of the example tube of  FIG. 17  or  18  to form the cuff of the example protective headwear of  FIG. 1  or  11 , respectively; 
         FIG. 20  illustrates a crown forming operation to complete the protective headwear of  FIGS. 1 and 11 ; 
         FIG. 21  illustrates a person wearing an example protective headwear in accordance with a third embodiment; 
         FIG. 22  illustrates the construction of the example protective headwear of  FIG. 21 ; 
         FIG. 23  illustrates the construction of the example pocket band in the protective headwear illustrated in  FIG. 22 ; 
         FIG. 24  illustrates the construction of an example pocket in the pocket band of the protective headwear of  FIG. 21 ; 
         FIG. 25  illustrates the protective insert retained in the example pocket of the pocket band illustrated in  FIG. 24 ; 
         FIG. 26  illustrates a cross-section of the example protective headwear of  FIG. 21 ; 
         FIG. 27  illustrates a person wearing the protective headwear of  FIG. 21  cutaway to reveal the protective insert retained by a pocket band in relation to the body and the cuff of the protective headwear; 
         FIG. 28  illustrates a person wearing an example protective headwear in accordance with a fourth embodiment; and 
         FIG. 29  illustrates a cross-section of the example protective headwear of  FIG. 28 . 
     
    
    
     DETAILED DESCRIPTION 
     A form-fitting protective headwear and a method of manufacturing the form-fitting protective headwear are disclosed herein. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of example embodiments. It will be evident, however, to one skilled in the art, that an example embodiment may be practiced without all of the disclosed specific details. 
       FIG. 1  illustrates a person  100  wearing an example protective headwear  102  in accordance with a first embodiment. The protective headwear  102  is configured to provide a combination of a significant protective function in an aesthetic form-factor, which improves desirability for wearing the protective headwear  102 . More superficially, the protective headwear  102  provides the appearance of an aesthetic stretchable hat, while at the same time providing a significant protective function, which encourages the use of the protective headwear  102  and reduces the potential for head injuries. 
     The protective headwear  102  can be made from manmade/synthetic materials, natural materials, and/or blended combinations thereof. For example, wool, cotton, acrylic, nylon, other natural or synthetic materials, and combinations thereof can be used. 
     The protective headwear  102  is shown to include a body  104  and a cuff  106 . The cuff  106  can be (but does not have to be) formed by cuffing or rolling an end portion of the body  102  over itself. The protective headwear  102  can be worn un-cuffed to cover the person&#39;s ears, or cuffed to partially cover the ears or completely above the ears. In some embodiments, a separate insertable cuff element (e.g., made of foam rubber, or other similar material) that is pliable and lightweight can be incorporated inside of and along the circumference of the cuff  106 , as will be described in greater detail hereinbelow. In other embodiments, the protective headwear  102  can also be cuff-less (e.g., the cuff  106  can be omitted) and/or a visor can be stitched or secured to the body  104 . As will be described in greater detail herein, the body  104  is configured to fit precisely and aesthetically over a person&#39;s head and to provide a protective function against head injury resulting from activities in which the person  100  engages. 
     The activities for which the protective headwear  102  will find implementation can include, for example, rollerblading, biking, hiking, skateboarding, touch football, soccer, field hockey, girls lacrosse, rock climbing, skiing, snowboarding, and ice-skating, as well as other sports and activities. In addition, other activities for which the protective headwear  102  will find implementation can include, for example, police, security, military and industrial applications. The foregoing list of activities is not exhaustive, and people engaged in other activities that are not enumerated can benefit from the protective function in an aesthetic form-factor provided by the protective headwear  102 . 
       FIG. 2  illustrates the construction of the example protective headwear  102  of  FIG. 1 . The protective headwear  102  includes a pocket band  201  and a plurality of protective inserts  204 . 
     The pocket band  201  is disposed about at least a portion of the interior of the protective headwear  102  and is configured to receive and retain the protective inserts  204  in a predetermined configuration that provides a protective function to the person&#39;s head when the person  100  wears the protective headwear  102 . 
     The pocket band  201  extends from the base stitching ( FIG. 3 , element  310 ) of the protective headwear  102  towards the apex or crown  206  of the protective headwear  102  such that the protective function can be provided to the head of the person  100 . The protective headwear  102 , and more particularly the pocket band  201  coupled with protective inserts  204 , is configured to at least partially or fully cover the frontal, parietal, temporal and occipital part of the person&#39;s head. 
     The pocket band  201  includes a plurality of pockets  202 , each of which is configured (e.g., sized and dimensioned) to receive and retain a respective protective insert  204 , such that the plurality of protective inserts  204  can be disposed in the predetermined configuration in the pocket band  201  of the protective headwear  102 . In some embodiments, six (6) pockets  202  are provided in the pocket band  201 . In other embodiments, there can be four (4) to twelve (12) pockets  202 . Fewer or greater number of pockets  202  can be provided in alternate embodiments. 
     The pockets  202  are disposed adjacently about the pocket band  201  such that the protective inserts  204  can be adjacently disposed (e.g., one next to the other), providing an almost continuous protective function about the protective headwear  102 . The pockets  202  will be described in greater detail below with reference to  FIG. 3 . In some embodiments, the pockets  202  can be equidistantly disposed about the pocket band  201 . In other embodiments, the pockets  202  can be disposed at different locations about the pocket band  201  based on the size and dimension of the respective protective inserts to be received into the pockets  202 , as will be described below. 
     The protective inserts  204  are configured to be disposed adjacently to one another in the respective pockets  202  of the pocket band  201 , providing an almost continuous protective function about the protective headwear  102 . The protective inserts  204  are independently situated or disposed in the respective pockets  202  of the pocket band  201  and can conform to the contours of the person&#39;s head as the protective headwear  102  stretches about the person&#39;s head. 
     In various embodiments, the protective inserts  204  are approximately triangular in shape and yet are curvilinear, such that they conform to the contours of the person&#39;s head, approximating or joining at the crown of the person&#39;s head to provide an almost continuous protective function at the apex or crown  206  of the protective headwear  102 . 
     In some embodiments, six (6) protective inserts  204  can be provided. In other embodiments, there can be four (4) to twelve (12) protective inserts  204 . Fewer or greater number of protective inserts  204  can be provided in alternate embodiments. The protective inserts  204  will be described in greater detail with reference to  FIGS. 4-6 . 
     The protective inserts  204  can be similarly or differently sized and/or dimensioned (e.g., same or different triangular slices) such that the combination of the protective inserts  204  conform to the contours of the person&#39;s head, approximating or joining at the crown of the person&#39;s head to provide an almost continuous protective function at the apex or crown  206  of the protective headwear  102 . For example, the protective inserts  204  in the front and/or the back of the protective headwear  102  can be wider triangular slices than the remaining slices therebetween. Other arrangements are possible of course. The pockets  202  can be adjusted based on the dimensions of the respective protective inserts  204 . 
     Moreover, at least one protective insert  204  can include an adhesive layer  208  (e.g., double-sided adhesive tape or other material) disposed atop at least a portion of the protective insert  204  to enable the insert  204  to be removeably secured in the pocket band  201 . In addition to or instead of adhesive layer  208 , another adhesive layer can also be disposed on the back of the protective insert  204 . In some embodiments, the protective inserts  204  with adhesive layers  208  can also be removeably secured inside headwear that may not be provided with the pocket band  201 . A variety of adhesive layers  208  can be used to enable the protective inserts  204  to be removeably secured in the pocket band  201  of headwear  102  or on the interior of other headwear that may not be provided with the pocket band  201 . 
       FIG. 3  illustrates the construction of an example pocket  202  in the pocket band  201  of  FIG. 2 . It should be noted that a plurality of pockets  202  can be formed in the pocket band  201  as illustrated in  FIG. 2 . For example, four (4) to twelve (12) pockets  202  can be formed in the pocket band  201 . The pocket  202  includes at least one opening  302 ,  304  and is defined by side stitchings  306 ,  308  and base stitching  310 . 
     The at least one opening  302 ,  304  is configured to receive the protective insert  204  into the pocket  202 . In some embodiments, two (2) openings are provided in which a first opening  302  is disposed at a first distance above the base stitching  310  and a second opening  304  is disposed at a second distance above the base stitching  310 . The first and second distances can be varied. For example, the second opening  304  can be disposed at the top-most extent  312  of the pocket band  201  (e.g., crease of the pocket band  201 ). 
     The second opening  304  can be offset from the top-most extent  312  of the pocket band  201 , to either the front or the back of the pocket band  201 . For example, the second opening  304  can be disposed in the back of the pocket band  201  between the pocket band  201  and the inside of the body  104 . As another example, the second opening  304  can also be disposed in the front of the pocket band  201 , similarly to the first opening  302 . 
     Other alternatives are possible in which one or more of the openings  302 ,  304  are disposed in the back of the pocket band  201  between the pocket band  201  and the inside of the body  104 . Such construction can allow both easy insertion of the protective insert  204 , while hiding the potentially unsightly openings  302 ,  304  to the interior of the protective headwear  102 . 
     Moreover, the openings  302 ,  304  are approximately centered in relation to the side stitchings  306 ,  308 . The openings  302 ,  304  are stretchable in order to receive the protective insert  204  into the pocket  202 . The openings  302 ,  304  can be formed to be more stretchable than the body  104  and the cuff  106  to facilitate insertion of the protective insert  204  into the pocket  202 . The first opening  302  and second opening  304  can have approximately the same dimension. Alternatively, the second opening  304  can be smaller than the first opening  302 , such that the protective insert  204  is initially received through the larger opening  302  and extends toward the apex or crown of the protective headwear  102  through the smaller opening  304  at the top-extent  312  of the pocket band  201 . 
     In other embodiments, only one (1) opening is provided in the pocket  202  to receive the protective insert  204  into the pocket  202 . More specifically, only the second opening  304  can be provided at the top-most extent  312  of the pocket band  201  (e.g., crease of the pocket band  201 ) or offset from the top-most extent  312  in the various alternatives as already described above. 
     The side stitchings  306 ,  308  of each pocket  202  extend approximately from the base stitching  310  and partially along the height of the pocket band  201  towards the apex or crown  206  of the protective headwear  102 . In some embodiments, the side stitchings  306 ,  308  can extend to approximately the first opening  302  in the pocket  202 . In other embodiments, the side stitchings  306 ,  308  can extend to the second opening  304 , and further can extend partially or fully to the top-most extent  312  of the pocket band  201 . 
     The side stitchings  306 ,  308  are further approximately angled towards one another and towards the apex or crown  206  of the protective headwear  102 . More specifically, the stitchings  306 ,  308  can be angled to approximate and accommodate the angulation of each protective insert  204 , such that the plural protective inserts  204  can be retained in a predetermined configuration with respect to one another in the respective pockets  202  and can provide an almost continuous protective function to the person&#39;s head when the person  100  wears the protective headwear  102 . 
     The side stitchings  306 ,  308  can be z-stitch patterns to provide stretchability about a person&#39;s head. Straight stitching patterns (e.g., using elastic thread) can also be used for the side stitchings  306 ,  308 . Other stitch patterns can be used for various advantages. 
     The base stitching  310  extends along the circumference of the pocket band  201  and is configured to provide a base or seat for each of the protective inserts  204 , which approximates and accommodates the base of each protective insert  204 , such that the plural protective inserts  204  can be retained in a predetermined configuration with respect to one another in the respective pockets  202  and can provide an almost continuous protective function to the person&#39;s head when the person  100  wears the protective headwear  102 . 
       FIG. 4  illustrates the construction of an example protective insert  204  of  FIG. 2  in accordance with a first embodiment. In the first embodiment, the example protective insert  204  includes a stack of four (4) layers  402 ,  406 ,  412 ,  418 . The layers  402 ,  406 ,  412 ,  418  of the protective insert  204  are configured to provide a protective function to the person  100  when wearing the protective headwear  102 . 
     The outermost layer  402  can be a durable and rigid plastic configured to provide impact-resistance from impacts which can cause serious trauma to the head of the person  100 . For example, the layer  402  can be a thermoplastic, such as a polycarbonate or polymethyl methacrylate (PMMA), or another plastic that is sufficiently rigid yet can deform without cracking or breaking from an impact associated with an accident and/or intentional act of another person. Other durable and rigid plastics and/or combinations of various materials can be used to provide impact-resistance from impacts which can cause serious trauma to the head of the person  100 . 
     In some embodiments, the outermost layer  402  is a polycarbonate having a thickness of approximately 0.09 inches to provide impact-resistance from general accidents, such as during industrial, sports or leisure activities. In other embodiments, the outermost layer  402  is a polycarbonate having a thickness of approximately 0.27 inches to provide impact-resistance (e.g., bulletproof resistance), such as during military, security and/or industrial activates. For example, the outermost layer  402  can have a thickness and be made of material(s) similar to bullet-proof glass. Other thicknesses can be provided based on the activity for which impact-resistance is desired. 
     The outermost layer  402  can include an opening or slit  404 . In such cases, the other layers  406 ,  412  and  418  also can include openings or slits  410 ,  416  and  420 , respectively. The openings  404 ,  410 ,  416  and  420  can approximate one another to provide a ventilation slit through the protective insert  204 . One or more additional ventilation slits can be provided though the protective insert  204 . The positioning and size of the ventilation slit can be changed. 
     The middle layers  406 ,  412  can be a pliable rubber (e.g., neoprene) configured to provide cushioning, as well as to mitigate and disperse (or distribute) the impact from the outermost layer  402  about the protective insert  204 . Other pliable rubbers, materials and/or combinations or materials can be used. For example, one or more of the middle layers  406 ,  412  can be elastomers. The middle layers  406 ,  412  can further provide alternating arrangements  409 ,  415  of respective openings  408 ,  414 . The openings  408 ,  414  can extend partially or fully through the middle layers  406 ,  412 . In some embodiments, the openings  408 ,  414  can also be air pockets that are internal or embedded in the middle layers  406 ,  412  (e.g., not extending through surfaces of the middle layers  406 ,  412 ). In some other embodiments, the openings  408 ,  414  can be omitted. 
     When the middle layers  406 ,  412  are assembled into the protective insert  204 , the respective openings  408 ,  414  are sealed to provide air pockets, which can absorb and disperse the impact from the outermost layer  402  about the protective insert  204 . The middle layers  406 ,  412  can have adhesive surfaces such that layers  402 ,  406 ,  412 ,  418  can be easily sealed with respect to one another to provide the foregoing air pockets. In some embodiments, the outermost layer  402  and the middle layer  406  can be sealed using a process known as overmolding. In such embodiments, one or more of the layers  412 ,  418  can have adhesive surfaces for sealing. In various embodiments, the alternating arrangements  409 ,  415  about the layers  406 ,  412  can be amended or changed. The shapes and dimensions of the respective openings  408 ,  414  can be different or the same in the various alternating arrangements  409 ,  415 . 
     In some embodiments, the middle layer  406  can have a thickness 0.25 inches, while the middle layer  412  can have a thickness of 0.125 inches. In these embodiments, a portion of the protective insert  204  covered by air pockets from the openings  408  in the alternating arrangement  409  can be larger than a portion of the protective insert  204  covered by air pockets from the openings  414  in the alternating arrangement  415 . Alternative thicknesses, arrangements and/or coverage distribution amongst the middle layers  406 ,  412  are of course possible. For example, the order of the middle layers  406 ,  412  can be reversed in relation to the outermost layer  402  and the innermost layer  418 . 
     It is important to note that the alternating arrangements  409 ,  415  enable air pockets formed from various openings  404 ,  414  to cover a substantial portion of the protective insert  204  in order to provide improved absorption and dispersal (or distribution) of the impact from the outermost layer  402  about the protective insert  204 . In some embodiments, the coverage of the protective insert  204  by the air pockets formed from various openings  404 ,  414  can be continuous. More specifically, the openings  404  of the arrangement  409  are approximately non-overlapping and approximately contiguous with the openings  414  of the alternating arrangement  415 , such that a substantial portion of the protective insert  204  can be provided (or covered) with air pockets, enhancing the absorption and distribution (e.g. deflection) of the impact about the at least one protective insert  204 , mitigating or eliminating the possibility of serious injury to the head. 
     The innermost layer  418  is configured to provide additional cushioning and to enclose or seal middle layers  406 ,  412  between the outermost layer  402  and the innermost layer  418 . The innermost layer  418  can be a pliable rubber (e.g., neoprene) and can have a thickness of 0.0625 inch. Other pliable rubbers or other materials can be used. For example, the innermost layer  418  can be an elastomer. In some embodiments, the innermost layer  418  can be omitted. 
     In various embodiments, the innermost layer  418  can cover the middle layers  406 ,  412  (particularly middle layer  412 ) partially or fully. The innermost layer  418  can cover a certain portion of the middle layer  412 , such as a bottom, middle, top or other portion. For example, the innermost layer  418  can cover a bottom portion (e.g., 25% to 50%, or a greater or smaller range) of the middle layer  412 . As another example, innermost layer  418  can cover a portion of the middle layer  412  that includes one or more of the openings  414  (e.g., partial or full arrangement  415  of openings  414 ), such as disposed about the bottom, middle, top or other portion of the middle layer  412 . 
       FIG. 5  illustrates the construction of an example protective insert  204  of  FIG. 2  in accordance with a second embodiment. In the second embodiment, the example protective insert  204  includes a stack of three (3) layers  502 ,  508 ,  516 . The layers  502 ,  508 ,  516  of the protective insert  204  are configured to provide a protective function to the person  100  when wearing the protective headwear  102 . 
     The outermost layer  502  can be a durable and rigid plastic configured to provide impact-resistance from impacts which can cause serious trauma to the head of the person  100 . For example, the outermost layer  502  can be a thermoplastic, such as a polycarbonate or another plastic that is sufficiently rigid yet can deform without cracking or breaking from an impact associated with an accident and/or intentional act of another person. Other durable and rigid plastics or combinations of materials can be used to provide impact-resistance from impacts which can cause serious trauma to the head of the person  100 . 
     In some embodiments, the outermost layer  502  is a polycarbonate having a thickness of approximately 0.09 inches to provide impact-resistance from general accidents, such as during sports, industrial or leisure activities. In other embodiments, the outermost layer  502  is a polycarbonate having a thickness of approximately 0.27 inches to provide impact-resistance (e.g., bulletproof resistance), such as during military, security and/or industrial activates. For example, the outermost layer  402  can have a thickness and be made of material(s) similar to bullet-proof glass. Other thicknesses can be provided based on the activity for which impact-resistance is desired. 
     The outermost layer  502  can include openings or slits  504 ,  506 . In such cases, the other layers  508 ,  516  also can include corresponding openings or slits  512 ,  514 ,  518 ,  520 , respectively. The openings slits  504 ,  506 ,  512 ,  514 ,  518 ,  520  can provide ventilation slits through the protective insert  204 . The number, positioning and size of the ventilation slits can be changed. 
     The middle layer  508  can be a pliable rubber (e.g., neoprene) configured to provide cushioning, as well as to mitigate and disperse the impact from the outermost layer  502  about the protective insert  204 . Other pliable rubbers or other materials can be used. For example, the middle layers  508  can be an elastomer. The middle layer  508  can provide an arrangement  511  of openings  510 . The openings  510  can extend partially or fully through the middle layer  508 . In some embodiments, the openings  510  can also be air pockets that are internal or embedded in the middle layer  508  (e.g., not extending through surfaces of the middle layer  508 ). In some other embodiments, the openings  510  can be omitted. 
     The middle layer  508  can further have adhesive surfaces that when the middle layer  508  is assembled into the protective insert  204 , the openings  510  can be easily sealed to provide air pockets, which can absorb and disperse the impact from the outermost layer  502  about the protective insert  204 . In some embodiments, the outermost layer  502  and the middle layer  508  can be sealed using a process known as overmolding. In such embodiments, the other layer  516  can have an adhesive surface for sealing. In various embodiments, the arrangement  511  can be changed. 
     In some embodiments, layer  508  can have a thickness between about 0.0625 inches and about 0.1875 inches. Alternating thicknesses of the middle layer  508  are of course possible. It is important to note that the arrangement  511  enables air pockets formed from openings  510  to cover a substantial portion of the protective insert  204  in order to provide absorption and dispersal the impact from the outermost layer  502  about the protective insert  204 . 
     The innermost layer  516  is configured to provide additional cushioning and to enclose or seal the middle layer  508  between the outermost layer  502  and the innermost layer  516 . The innermost layer  516  can be a pliable rubber (e.g., neoprene) and can have a thickness of 0.0625 inch. Other pliable rubbers or other materials can be used. For example, the innermost layer  516  can be an elastomer. In some embodiments, the innermost layer  516  can be omitted. 
     In various embodiments, the innermost layer  516  can cover the middle layer  508  partially or fully. The innermost layer  516  can cover a certain portion of the middle layer  508 , such as a bottom, middle, top or other portion. For example, the innermost layer  516  can cover a bottom portion (e.g., 25% to 50%, or a greater or smaller range) of the middle layer  508 . As another example, innermost layer  516  can cover a portion of the middle layer  508  that includes one or more of the openings  510  (e.g., partial or full arrangement  511  of openings  510 ), such as disposed about the bottom, middle, top or other portion of the middle layer  508 . 
       FIG. 6  illustrates the construction of an example protective insert  204  of  FIG. 2  in accordance with a third embodiment. In the third embodiment, the example protective insert  204  also includes a stack of three (3) layers  602 ,  608 ,  616 . The layers  602 ,  608 ,  616  of the protective insert  204  are configured to provide a protective function to the person  100  when wearing the protective headwear  102 . 
     The outermost layer  602  can be a durable and rigid plastic configured to provide impact-resistance from impacts which can cause serious trauma to the head of the person  100 . For example, the outermost layer  602  can be a thermoplastic, such as a polycarbonate or another plastic that is sufficiently rigid yet can deform without cracking or breaking from an impact associated with an accident and/or intentional act of another person. Other durable and rigid plastics or combinations of materials can be used to provide impact-resistance from impacts which can cause serious trauma to the head of the person  100 . 
     In some embodiments, the outermost layer  602  is a polycarbonate having a thickness of approximately 0.09 inches to provide impact-resistance from general accidents, such as during sports, industrial or leisure activities. In other embodiments, the outermost layer  602  is a polycarbonate having a thickness of approximately 0.27 inches to provide impact-resistance (e.g., bulletproof resistance), such as during military, security and/or industrial activates. For example, the outermost layer  402  can have a thickness and be made of material(s) similar to bullet-proof glass. Other thicknesses can be provided based on the activity for which impact-resistance is desired. 
     The outermost layer  602  can include openings or slits  604 ,  606 . In such cases, the other layers  608 ,  616  also can include corresponding openings or slits  612 ,  614 ,  618 ,  620 , respectively. The openings  604 ,  606 ,  612 ,  614 ,  618 ,  620  can provide ventilation slits through the protective insert  204 . The number, positioning and size of the ventilation slits can be changed. 
     The middle layer  608  can be a pliable rubber (e.g., neoprene) configured to provide cushioning, as well as to mitigate and disperse the impact from the outermost layer  602  about the protective insert  204 . Other pliable rubbers or other materials can be used. For example, the middle layers  608  can be an elastomer. More specifically, the middle layer  608  can provide an arrangement  611  of openings  610 . The openings  610  can extend partially or fully through the middle layer  608 . In some embodiments, the openings  610  can also be air pockets that are internal or embedded in the middle layer  608  (e.g., not extending through surfaces of the middle layer  608 ). In some other embodiments, the openings  610  can be omitted 
     The middle layer  608  can have adhesive surfaces such that the middle layer  608  is assembled into the protective insert  204 , the openings  610  can be easily sealed to provide air pockets, which can absorb and disperse the impact from the outermost layer  602  about the protective insert  204 . In some embodiments, the outermost layer  602  and the middle layer  608  can be sealed using a process known as overmolding. In such embodiments, the other layer  616  can have an adhesive surface for sealing. In various embodiments, the arrangement  611  can be changed. The pockets in the third embodiment have a more circular shape or oblong shape (without sharp corners), which can provide for a more uniform distribution or dispersal of the impact from the outermost layer  602  about the protective insert  204 . 
     In some embodiments, layer  608  can have a thickness between about 0.0625 inches and about 0.1875 inches. Alternating thicknesses of the middle layer  608  are of course possible. It is important to note that the arrangement  611  enables air pockets formed from openings  610  to cover a substantial portion of the protective insert  204  in order to provide absorption and dispersal the impact from the outermost layer  602  about the protective insert  204 . 
     The innermost layer  616  is configured to provide additional cushioning and to enclose or seal the middle layer  608  between the outermost layer  602  and the innermost layer  616 . The innermost layer  616  can be a pliable rubber (e.g., neoprene) and can have a thickness of 0.0625 inch. Other pliable rubbers or other materials can be used. For example, the middle layers  616  can be an elastomer. In some embodiments, the innermost layer  616  can be omitted. 
     In various embodiments, the innermost layer  616  can cover the middle layer  608  partially or fully. The innermost layer  616  can cover a certain portion of the middle layer  608 , such as a bottom, middle, top or other portion. For example, the innermost layer  616  can cover a bottom portion (e.g., 25% to 50%, or a greater or smaller range) of the middle layer  608 . As another example, innermost layer  616  can cover a portion of the middle layer  608  that includes one or more of the openings  610  (e.g., partial or full arrangement  611  of openings  610 ), such as disposed about the bottom, middle, top or other portion of the middle layer  608 . 
       FIG. 7  illustrates a cross-section of the example protective headwear  102  in accordance with the first embodiment of  FIG. 1 . 
     The protective headwear  102 —including the body  104 , cuff  106  and pocket band  201 —can be weaved in a continuous weaving process on a loom or another automated weaving machine. The body  104  and cuff  106  of the headwear  102  can be weaved from a thread and/or weave of a first thickness  702 . 
     During the continuous weaving process, the thread and/or weave of the first thickness  702  can be automatically continued with a thread and/or a weave of a second thickness  704  at approximately location  708  to form the pocket band  201 , such that the protective headwear  102  is of a continuous and/or monolithic construction. For example, the first thickness  702  can be approximately 0.25 inches, while the second thickness  702  can be approximately 0.03 inches. Other first and second thicknesses  702 ,  704  can of course be used. It is noted, however, that the aim is to provide a pocket band  201  having minimized thickness in relation to the thickness of the body  104 , while also providing stretchability to receive protective inserts  204  into the pocket band  201  and durability/strength to retain the protective inserts  204  in the pocket band  201 . 
     At the top-most extent  312  of the pocket band  201 , the pocket band  201  is folded (e.g., providing a crease in the pocket band  201 ). More specifically, an end  706  of the pocket band  201  is tucked or folded to the interior of the protective headwear  102 , and more particularly to the interior of the body  104 , and the base stitching  310  is applied at approximately location  708  to capture or secure the end  706 , completing the pocket band  201  and delineating the pocket band  201  from the body  104  and the cuff  106 . In some embodiments, a separate insertable cuff element  710  (e.g., made of foam rubber, or other similar material) that is pliable and lightweight can be incorporated inside of and along the circumference of the cuff  106 . The thickness, height and diameter of the cuff element  710  can vary based on dimensions of the cuff  106  of the headwear  102 . 
     As illustrated, the pocket band  201  is free floating with respect to the body  104  of the protective headwear  102 , such that the pocket band  201  can provide application-specific or precise fit and positioning of plural protective inserts  204  for various head sizes to effectively reduce and/or eliminate head injuries. As described previously herein, one or both openings  302 ,  304  can be provided to allow insertion of the protective insert  204  into the pocket  202 . 
     As further illustrated, the second thickness  704  can be reduced from the first thickness  702  (e.g., approximately by half or smaller from the first thickness  702 ) such that sufficient space can be provided in the pocket  202  of the pocket band  201  to receive a protective insert  204 , providing an aesthetic, comfortable and inexpensive form-factor that can result in increased desirability and usability of protective headwear  102  to mitigate and/or eliminate head injuries. 
       FIG. 8  illustrates a cross-section of the example protective headwear  102  of  FIG. 7  with the protective insert  204  disposed in the pocket  202 . 
     As illustrated, the base stitching  310  further provides a base to retain the protective insert  204  in the pocket  202 . As described previously herein, the protective insert  204  is inserted into the pocket  202  of the pocket band  201  through either the opening  302  and followed by the opening  304 , if two (2) openings are provided, or through the opening  304  if only one (1) opening is provided. 
     The openings  302 ,  304  are stretchable to receive the protective insert  204  into the pocket  202  (e.g., based on the stretchable material from which the protective headwear  102  is made). The adhesive layer  208  illustrated in  FIG. 2 , if provided atop a portion of the protective insert  204  that is received in the pocket  202 , can enable the protective insert  204  to be removeably secured in relation to the pocket band  201 . Accordingly, once the protective insert  204  is received into the pocket  202 , opening  304  can contour about the triangular shape of the protective insert  204  to retain or removeably secure the protective insert in the pocket  202 . 
     As further illustrated, the pocket band  201  with the inserted protective insert  204  is free floating with respect to the body  104  of the protective headwear  102 , such that the pocket band  201  can provide application-specific or precise fit and positioning of the plural protective inserts  204  for various head sizes (e.g., such as the head  802  of the person  100 ) to effectively reduce and/or eliminate head injuries. 
     Moreover, the second thickness  704  compared to thickness  702  provides space in the pocket  202  of the pocket band  201  for the protective insert  204 , facilitating an aesthetic, comfortable and inexpensive form-factor that can result in increased desirability and usability of protective headwear  102  to mitigate and/or eliminate head injuries. 
       FIG. 9  illustrates a person  100  wearing the protective headwear  102  of  FIG. 1  cutaway to expose or reveal the protective insert  204  in relation to the body  104  and cuff  106 . 
     Plural protective inserts  204  are secured by the pocket band  201 —and more particularly, by the respective pockets  202  of the pocket band  201 —around the head of the person  100  and conform or contour to the head of the person  100 , providing a protective function to the frontal, parietal, temporal and occipital parts of the person&#39;s head. 
     The protective inserts  204  provide an almost continuous protective function amongst and between the protective inserts  204 , about the circumference of the protective band  201  and through to the apex or crown  206  of the protective headwear  102 . 
       FIG. 10  illustrates a cross-section of the protective insert  204  in accordance with the first embodiment of  FIG. 4  to show the example protective function. 
     As illustrated, an example impact  1002  is delivered to the protective insert  204  illustrated in the cutaway of  FIG. 9 . More specifically, the impact  1002  can be delivered by accident or willfully by another person to the outermost layer  402 , which can deform but is configured not to crack or break. The force of the impact  1002  is absorbed and distributed or dispersed through the layers  402 ,  406 ,  412 ,  418  as follows. 
     The sealed air pockets  408 ,  414  in the respective middle layers  406 ,  412  distribute or disperse the impact  1002  about the protective insert  204  as illustrated by arrows  1004 ,  1006 ,  1008 . More specifically, the force of the impact  1002  cannot fully continue through the air pockets  404 ,  414 . When the air that is sealed (or trapped) in the air pockets  408 ,  414  is compressed by the impact  1002 , the air pockets  408 ,  414  deflect or distribute a portion of the force of the impact  1002  to the surrounding layers  402 ,  406 ,  412 ,  418  that are contiguous to the air pockets  408 ,  414 . The trapped air deforms the pliable middle and innermost layers  406 ,  412 ,  418 . These layers  406 ,  412  absorb portions of the force of the impact  1002  to provide cushioning to the head of the person  100 , while some portions of the force of the impact  1002  are also dispersed and spread over the outermost layer  402 . 
       FIG. 11  illustrates a person  100  wearing an example protective headwear  1102  in accordance with a second embodiment. The protective headwear  1102  is configured to provide a combination of a significant protective function in an aesthetic form-factor, which improves desirability for wearing the protective headwear  1102 . More superficially, the protective headwear  1102  provides the appearance of an aesthetic stretchable hat, while at the same time providing a significant protective function, which encourages the use of the protective headwear  1102  and reduces the potential for head injuries. 
     The protective headwear  1102  can be made from manmade/synthetic materials, natural materials, and/or blended combinations thereof. For example, wool, cotton, acrylic, nylon, other natural/synthetic materials, and combinations thereof can be used. The protective headwear  1102  is shown to include a body  1104  and a cuff  1106 . The cuff  1106  can be (but does not have to be) formed by cuffing or rolling an end portion of the body  1102  over itself. In some embodiments, a separate insertable cuff element (e.g., made of foam rubber, or other similar material) that is pliable and lightweight can be incorporated inside of and along the circumference of the cuff  106 , as will be described in greater detail hereinbelow. In other embodiments, the protective headwear  1102  can also be cuff-less (e.g., the cuff  1106  can be omitted) and/or a visor can be stitched or secured to the body  1104 . The protective headwear  1102  can be worn un-cuffed to cover the person&#39;s ears, or cuffed to partially cover the ears or completely above the ears. 
     The body  1104  is configured to fit precisely and aesthetically over a person&#39;s head and to provide a protective function against head injury resulting from activities in which the person  100  engages. The activities for which the protective headwear will find implementation can include, for example, rollerblading, biking, hiking, skateboarding, touch football, soccer, field hockey, girls lacrosse, rock climbing, skiing, snowboarding, and ice-skating, as well as other sports and activities as described herein. 
       FIG. 12  illustrates the construction of the example protective headwear  1102  of  FIG. 11 . The protective headwear  1102  includes a pocket band  1201  and a plurality of protective inserts  204 . In this second embodiment, the pocket band  1201  can be provided (e.g., weaved) separately from the headwear  1102  and then attached (e.g., stitched) to the protective headwear  1102 . 
     Moreover, in various other embodiments the pocket band  1201  can be manufactured or provided as a liner, for example, which can remain separate from the protective headwear  1102 , such that the protective headwear  1102  can be completed when the protective headwear  1102  (or another cap, hat or the like) is worn over the combination of the liner (e.g., pocket band  1201 ) and the protective inserts  204 . 
     Now with further reference to  FIG. 12 , the pocket band  1201  is disposed about at least a portion of the interior of the protective headwear  1102  and is configured to receive and retain the protective inserts  204  in a predetermined configuration that provides a protective function to the person&#39;s head when the person  100  wears the protective headwear  1102 . 
     The pocket band  1201  extends from the base stitching  1210  of the protective headwear  1102  towards the apex or crown  1216  of the protective headwear  1102  such that the protective function can be provided to the head of the person  100 . The protective headwear  1102 , and more particularly the pocket band  1201  coupled with protective inserts  204 , is configured to at least partially or fully cover the frontal, parietal, temporal and occipital part of the person&#39;s head. 
     The pocket band  1201  includes a plurality of pockets  1202 , each of which is defined by the side stitchings  1206 ,  1208  and the base stitching  1210 . Each of the pockets  1202  is configured (e.g., sized and dimensioned) to receive and retain a respective protective insert  204 , such that the plurality of protective inserts  204  can be disposed in the predetermined configuration in the pocket band  1201  of the protective headwear  1102 . In some embodiments, six (6) pockets  1202  are provided in the pocket band  1201 . In other embodiments, there can be four (4) to twelve (12) pockets  1202 . Fewer or greater number of pockets  1202  can be provided in alternate embodiments. 
     The plurality of pockets  1202  are disposed adjacently about the pocket band  1201  such that the protective inserts  204  can be adjacently disposed (e.g., one next to the other), providing an almost continuous protective function about the protective headwear  1102 . In some embodiments, the pockets  1202  can be equidistantly disposed about the pocket band  1201 . In other embodiments, the pockets  1202  can be disposed at different locations about the pocket band  1201  based on the size and dimension of the respective protective inserts to be received into the pockets  1202 . 
     Each pocket  202  includes at least one opening  1212 ,  1214 , which is configured to receive the protective insert  204  into the pocket  1202 . In some embodiments, two (2) openings are provided in which a first opening  1212  is disposed at a first distance above the base stitching  1210  and a second opening  1214  is disposed at a second distance above the base stitching  1210 . The first and second distances can be varied. For example, the second opening  1214  can be disposed at the top-most extent  1218  of the pocket band  1201  (e.g., crease of the pocket band  1201 ). 
     The second opening  1214  can be offset from the top-most extent  1218  of the pocket band  1201 , to either the front or the back of the pocket band  1201 . For example, the second opening  1214  can be disposed in back of the pocket band  1201  between the pocket band  1201  and the inside of the body  1104 . As another example, the second opening  1214  can also be disposed in front of the pocket band  1201 , similarly to the first opening  1212 . Other alternatives are possible in which one or more of the openings  1212 ,  1214  are disposed in the back of the pocket band  1201  between the pocket band  1201  and the inside of the body  1104 . Such construction can allow both easy insertion of the protective insert  1204 , while hiding the potentially unsightly openings  1212 ,  1214  to the interior of the protective headwear  1102 . 
     Moreover, the openings  1212 ,  1214  can be approximately centered in relation to the side stitching  1206 ,  1208 . The openings  1212 ,  1214  are stretchable in order to receive the protective insert  204  into the pocket  1202 . The openings  1212 ,  1214  can be formed to be more (or less) stretchable than the body  104 . The first opening  1212  and second opening  1214  can have approximately the same dimension. Alternatively, the second opening  1214  can be smaller than the first opening  1214 , such that the protective insert  204  is initially received through the larger opening  1212  and extends toward the apex or crown  1216  of the protective headwear  1102  through the smaller opening  1214  at the top-extent  1218  of the pocket band  1201 . The first and second openings  1212 ,  1214  can also have the same or different levels of stretchability with respect to one another and with respect to the body  1104  and the cuff  1106 . 
     In other embodiments, only one (1) opening is provided in the pocket  1202  to receive the protective insert  204  into the pocket  1202 . More specifically, only the second opening  1214  can be provided at the top-most extent  1218  of the pocket band  1201  (e.g., crease of the pocket band  201 ) or offset from the top-most extent  1218  in the various alternatives as already described above. 
     The side stitchings  1206 ,  1208  of each pocket  1202  extend approximately from the base stitching  1210  and partially along the height of the pocket band  1201  towards the apex or crown  1216  of the protective headwear  1102 . In some embodiments, the side stitchings  1206 ,  1208  can extend to approximately the first opening  1212  in the pocket  1202 . In other embodiments, the side stitchings  1206 ,  1208  can extend to the second opening  1214 , and further can extend partially or fully to the top-most extent  1218  of the pocket band  1201 . 
     The side stitchings  1206 ,  1208  are further approximately angled towards one another and towards the apex or crown  1216  of the protective headwear  1102 . More specifically, the stitchings  1206 ,  1208  can be angled to approximate and accommodate the angulation of each protective insert  204 , such that the plural protective inserts  204  can be retained in a predetermined configuration with respect to one another in the respective pockets  1202  and can provide an almost continuous protective function to the person&#39;s head when the person  100  wears the protective headwear  1102 . 
     The side stitchings  1206 ,  1208  can be z-stitch patterns to provide stretchability about a person&#39;s head. Straight stitching patterns (e.g., using elastic thread) can also be used for the side stitchings  1206 ,  1208 . Other stitch patterns can be used for various advantages. 
     The base stitching  1210  can be a z-stitch pattern and extends along the circumference of the pocket band  1201 . The base stitching  1210  is configured to provide a base or seat for each of the protective inserts  204 , approximating and accommodating the base of each protective insert  204 , such that the plural protective inserts  204  can be retained in a predetermined configuration with respect to one another in the respective pockets  1202  and can provide an almost continuous protective function to the person&#39;s head when the person  100  wears the protective headwear  1102 . 
     The base stitching  1210  is further configured to secure the separately weaved or manufactured pocket band  1201  to the interior of the protective headwear  1102  as described in greater detail below. As described hereinabove, the pocket band  1201  can be manufactured or provided as a liner separate from the protective headwear  1102 , such that the protective headwear  1102  can be completed when the protective headwear  1102  (or another cap, hat or the like) is worn over the combination of the liner (e.g., pocket band  1201 ) and protective inserts  204 . In such cases, the base stitching  1210  can be applied to the pocket band  1201  to enclose and complete the pockets  1202  of the pocket band  1201 . 
     The protective inserts  204  are configured to be disposed adjacently to one another in the respective pockets  1202  of the pocket band  1201 , providing an almost continuous protective function about the protective headwear  1102 . The protective inserts  204  are independently situated or disposed in the respective pockets  1202  of the pocket band  1201  and can conform to the contours of the person&#39;s head as the protective headwear  1102  stretches about the person&#39;s head. 
     The protective inserts  204  are described in greater detail with reference to  FIGS. 4-6  hereinabove. In some embodiments, six (6) protective inserts  204  can be provided. In other embodiments, there can be four (4) to twelve (12) protective inserts  204 . Fewer or greater number of protective inserts  204  can be provided in different embodiments based on the number of pockets  1202 . 
     As described hereinabove, the protective inserts  204  can also include adhesive layers  208  to enable the protective inserts  208  to be removeably secured in the pocket band  1201  of headwear  1102  or on the interior of other headwear that may not be provided with the pocket band  1201 . 
       FIG. 13  illustrates a cross-section of the example protective headwear  1102  in accordance with the second embodiment of  FIG. 11 . 
     The pocket band  1201  can be weaved in a first weaving process on a loom or another automated weaving machine, and can be weaved from a thread and/or weave of the first thickness  1302 . 
     The body  1104  and cuff  1106  can be weaved in a second weaving process on a loom or another automated weaving machine, and the pocket band  1201  can then be attached to the body  1104  and cuff  1106 . The protective headwear  1102  can be cuff-less and the pocket band  1201  can thus be attached to the body  1104 . The first and second weaving processes can be contemporaneous, sequential or can be performed at various times. The body  1104  and cuff  1106  of the protective headwear  1102  can be weaved from a thread and/or weave of a second thickness  1304 . 
     The second thickness  1304  can be reduced from the first thickness  1302  (e.g., approximately by half or smaller from the first thickness) such that sufficient space can be provided in the pocket  1202  of the pocket band  1201  to receive a protective insert  204 , providing an aesthetic, comfortable and inexpensive form-factor that can result in increased desirability and usability of protective headwear  102  to mitigate and/or eliminate head injuries. The first and second thicknesses  1302 ,  1304  can be same as or different than the first and second thicknesses  702 ,  704 , as described in relation to the first embodiment of the protective headwear  102  in  FIG. 7 . 
     After the second weaving process, the pocket band  1201  is attached or secured by ends  1306  to the protective headwear  1102  to form the pocket band  1201 , such that the protective headwear  1102  can receive and retain plural protective inserts  204  in the pockets  1204  of the pocket band  1201 . 
     At the top-most extent  1218  of the pocket band  1201 , the pocket band  1201  is folded (e.g., providing a crease in the pocket band  1201 ). More specifically, the ends  1306  of the pocket band  1201  are secured to the protective headwear  1102  by the base stitching  1210 , completing the pocket band  1201  and the cuff  1106  (if provided), as well as delineating the pocket band  1201  from the body  1104  and the cuff  1106  (if provided). In some embodiments, a separate insertable cuff element  1308  (e.g., made of foam rubber, or other similar material) that is pliable and lightweight can be incorporated inside of and along the circumference of the cuff  1106 . The thickness, height and diameter of the cuff element  1308  can vary based on dimensions of the cuff  1106  of the headwear  1102 . 
     As illustrated, the pocket band  1201  is free floating with respect to the body  1104  of the protective headwear  1102 , such that the pocket band  1201  can provide application-specific or precise fit and positioning of plural protective inserts  204  for various head sizes to effectively reduce and/or eliminate head injuries. As described previously herein, one or both openings  1212 ,  1214  can be provided to allow insertion of the protective insert  204  into the pocket  1202 . 
     As further illustrated, the second thickness  1304  can be reduced from the first thickness  1302  (e.g., approximately by half or smaller from the first thickness  1302 ) such that sufficient space can be provided in the pocket  1202  of the pocket band  1201  to receive a protective insert  204 , providing an aesthetic, comfortable and inexpensive form-factor that can result in increased desirability and usability of protective headwear  1102  to mitigate and/or eliminate head injuries. 
       FIG. 14  illustrates a cross-section of the example protective headwear  1102  of  FIG. 13  with the protective insert  204  disposed in the pocket  1202 . 
     As illustrated, the base stitching  1210  further provides a base to retain the protective insert  204  in the pocket  1202 . As described previously herein, the protective insert  204  is inserted into the pocket  1202  of the pocket band  1201  through either the opening  1212  and followed by the opening  1214 , if two (2) openings are provided, or through the opening  1214  if only one (1) opening is provided. 
     The openings  1212 ,  1214  are stretchable to receive the protective insert  204  into the pocket  1202  (e.g., based on the stretchable material from which the protective headwear  1102  is made). The adhesive layer  208  illustrated in  FIG. 12 , if provided atop a portion of the protective insert  204  that is received in the pocket  1202 , can enable the protective insert  204  to be removeably secured in relation to the pocket band  1201 . Accordingly, once the protective insert  204  is received into the pocket  1202 , the opening  1214  can contour about the approximately triangular shape of the protective insert  204  to retain or removeably secure the protective insert  204  in the pocket  1202 . 
     As further illustrated, the pocket band  1201  with the inserted protective insert  204  is free floating with respect to the body  1104  of the protective headwear  1102 , such that the pocket band  1201  can provide application-specific or precise fit and positioning of the plural protective inserts  204  for various head sizes (e.g., such as the head  1402  of the person  100 ) to effectively reduce and/or eliminate head injuries. 
     Moreover, the second thickness  1304  compared to the first thickness  1302  provides space in the pocket  1202  of the pocket band  1201  for the protective insert  204 , facilitating an aesthetic, comfortable and inexpensive form-factor that can result in increased desirability and usability of protective headwear  102  to mitigate and/or eliminate head injuries. 
       FIGS. 15-20  illustrate methods of manufacturing the example protective headwear  102 ,  1102  of  FIGS. 1 ,  11 , respectively.  FIGS. 15-17 ,  19  and  20  illustrate an example method of manufacturing the example protective headwear  102  of  FIG. 1 .  FIG. 18  illustrates an example method of manufacturing the example protective headwear  1102  of  FIG. 11 . The methods of manufacturing the protective headwear  102 ,  1102  of  FIGS. 1 ,  11  will be described in greater detail below. 
       FIG. 15  illustrates construction of an example tube  1500  made of stretchable or elastic woven fabric (thread), which can be formed into the protective headwear  102 ,  1102 , respectively. The tube  1500  is defined by edges  1508 ,  1510  and includes at least one plurality of openings  1503 ,  1504  about the tube  1500 . In some embodiments, only a first plurality of openings  1503  is provided. In other embodiments, the first plurality of openings  1503  and second plurality of openings  1504  are provided. At least one or more of the edges  1508 ,  1510  can be finished or reinforced. For example, the edge  1508  can be finished. In some cases, one or more of the edges  1508 ,  1510  can be unfinished. For example, the edge  1510  can be unfinished. 
     In accordance with the method, the tube  1500  is initially woven or formed. In some embodiments, the tube  1500  can be weaved in a continuous weaving process (e.g., via a loom or another weaving machine) using a circular weave from the first edge  1508  to the second edge  1510 . More specifically, the tube  1500  can be weaved to have a circumference of approximately 22 inches and a length (between edges  1508 ,  1510 ) from about 16 inches to about 20 inches. Alternative dimensions for the circumference and the length can be used. As will be described herein, the circumference of the tube  1500  can be gradually reduced or tapered along a portion of tube  1500  to provide a gradually reduced or tapered circumference of the pocket band  201 ,  1201  toward the apex or crown  206 ,  1216  of the headwear  102 ,  1102 . During the same or continuous weaving process, the at least one plurality of openings  1503 ,  1504  can be formed or weaved into the tube  1500 . The at least one plurality of openings  1503 ,  1504  can be finished or reinforced about the openings. 
     Moreover, the stretchability or elasticity of different portions of the headwear  102 ,  1102  can be varied during the same or continuous weaving process. In some embodiments, a first portion of the tube  1500  that will form the body  104  and cuff  106  can be woven from a woven fabric (thread) and/or a weave that provides a first order (level) of stretchability or elasticity, while a second portion of the tube  1500  that will form the pocket band  201  and the at least one plurality of openings  1503 ,  1504  openings can be woven from a woven fabric (thread) and/or a weave that provides a second order (level) of stretchability or elasticity. The second level can be more (or less) stretchable or elastic than the first level. In other embodiments, a third portion of the tube  1500  in which the at least one plurality of openings  1503 ,  1504  will formed can be woven from a woven fabric (thread) and/or a weave that provides a third order (level) of stretchability or elasticity. The third level can be more (or less) stretchable or elastic than the second level (and/or the first level). 
     In other embodiments of the method, the tube  1500  can be formed as follows. More specifically, the tube  1500  (including the at least one plurality of openings  1503 ,  1504 ) initially can be weaved as a flat material in a continuous weaving process (e.g., via a loom or another weaving machine) from the first edge  1508  to the second edge  1510 . The edges  1508 ,  1510  can be similarly finished or unfinished. During the same or continuous weaving process, the at least one plurality of openings  1503 ,  1504  can be formed or weaved into the tube  1500  (flat material) from a third edge to a fourth edge. The at least one plurality of openings  1503 ,  1504  can be finished or reinforced about the openings. Thereafter, the flat material can be rolled and the third and fourth edges joined in a stitching operating by a stitching  1502  to form the tube  1500 , which can have a circumference of approximately 22 inches and a length (between edges  1508 ,  1510 ) from about 16 inches to about 20 inches. Alternative dimensions for the circumference and the length can be used. 
     Reference  1506  indicates a first fold as will be described in greater detail below. The edge of the first fold  1506  will form the edge of the cuff  106 , as illustrated in  FIG. 20  and described in greater detail below. 
       FIG. 16  illustrates a first folding operation shown along a cross-section of the example tube  1500 . References  1602 ,  1604  indicate a second fold and a third fold, respectively, as will be described in greater detail below. References  1606 ,  1608  indicate a first portion and a second portion of the tube  1500 , respectively, as will also be described in greater detail below. The first portion  1606  extends from the edge  1510  to the third fold  1604 . The second portion  1608  extends from the third fold  1604  to the edge  1508 . 
     As illustrated, the edge  1508  is folded to the interior of the tube  1500  at the first fold  1506  to provide a first folded portion  1601  that extends from the first fold  1506  to the edge  1508 . 
     The first portion  1606  of the tube  1500  can be weaved from a woven fabric (thread) and/or a weave that provides a first order (level) of stretchability or elasticity, while the second portion  1608  of the tube  1500  that will form the pocket band  201  and the at least one plurality of openings  1503 ,  1504  openings can be weaved from a woven fabric (thread) and/or a weave that provides a second order (level) of stretchability or elasticity. 
     As further illustrated in  FIG. 16 , the first portion  1606  can have a first thickness, while the second portion  1608  can have a second thickness (e.g., the second thickness of the second portion  1608  approximately half or less the first thickness of the first portion  1606 ). Moreover, the circumference of the second portion  1608  can be gradually reduced or tapered along a first part of the tube  1500  between the second fold  1602  and third fold  1604 . Similarly, the circumference of the second portion  1608  can be gradually and reciprocally increased from the finally reduced circumference to the original circumference of tube  1500  along a second part of the tube  1500  between second fold  1602  and edge  1508 , such that when the second portion  1608  is folded at the second fold  1602 , the reduced circumferences of first and second parts approximate each other. 
     In some embodiments, a separate insertable cuff element  710  (e.g., made of foam rubber, or other similar material) that is pliable and lightweight can be incorporated along portion  1606 , from and between first fold  1506  and third fold  1604 , and along the circumference of tube  1500 , which will form the cuff  106 . The thickness, height and diameter of the cuff element  710  can vary based on dimensions of the cuff  106  to formed, as shown in greater detail in  FIG. 17 . 
       FIG. 17  illustrates a second folding operation and a stitching operation shown along the cross-section of the example tube  1500  to form the body  104 , cuff  106  and pocket band  201 . 
     As illustrated, during the second folding operation the edge  1508  again is folded to the interior of the tube  1500  at approximately the second fold  1602  to approximately the third fold  1604 , such that the plurality of openings  1503  are approximately at the second fold  1602 . In various embodiments, the opening  1503  can be offset from the second fold  1602  by modifying the length of the first folded portion  1601  and/or the second potion  1608 . 
     During the stitching operation, a base stitching  1704  is stitched at location  1702  through the second portion  1608  and the first portion  1606  of the tube  1500 , such that the edge  1508  is secured between the second portion  1608  and the first portion  1606 . This forms the pocket band  201  about the circumference of the tube  1500 , as illustrated in  FIG. 20 . As described herein, the pocket band  201  can now have a gradually-reduced circumference along its height toward the apex or crown  206 . This also forms the cuff  106  about the circumference of the tube  1500 . The base stitching  1704  secures the insertable cuff element  710  inside the cuff  106  in those embodiments that provide the insertable cuff element  710 . 
     Further with reference to the stitching operation, at each of the at least one opening  1503 ,  1504  (e.g., at each pair of openings  1503 ,  1504  or at each opening  1503  if only one opening is provided), side stitchings  1706 ,  1708  are stitched through the folded second portion  1608  only to form each of the pockets  202  that a free floating with respect to the first portion  1606 . The side stitchings  1706 ,  1708  extend from about the base stitching  1704  partially towards the fold  1602  and can be angled with respect to one another in order to approximate the protective insert  204 . 
       FIG. 18  illustrates an example method of manufacturing the example protective headwear  1102  of  FIG. 11 . More specifically, the tube  1500  of  FIG. 15  can be modified such that only the first portion  1606  is provided (weaved), but the second portion  1608  that extends from the third fold  1604  is not provided (weaved) as part of the tube  1500 . The tube  1500  as modified (e.g., the first portion  1606 ) is the folded at the first fold  1506  as shown in  FIG. 16 . In some embodiments, a separate insertable cuff element  1308  (e.g., made of foam rubber, other similar material) that is pliable and lightweight can be incorporated along portion  1606 , from and between first fold  1506  and third fold  1604 , and along the circumference of tube  1500  as modified, which will form the cuff  1106 . The thickness, height and diameter of the cuff element  1308  can vary based on dimensions of the cuff  106  to formed, as shown in greater detail in  FIG. 19 . 
     Thereafter, a separately formed pocket band  1802 —including at least one plurality of openings  1806 ,  1808  and folded about a fold  1804  to form a first portion  1810  and second portion  1812 —is abutted or placed adjacently to the folded first portion  1606  at about location  1814 . As described herein, the separately formed pocket band  1802  can similarly be formed such that it has a gradually-reduced circumference along its height toward the apex or crown  206 . Each of the first and second portions  1810 ,  1812  can have a thickness that is reduced (e.g., half or smaller) than the thickness of the tube  1500  as modified (e.g., thickness of the first portion  1606 ). 
     During the stitching operation, a base stitching  1816  is stitched at the location  1814  through the folded tube  1500  (as modified) and through the portions  1810 ,  1812 , such that the pocket band  1802  and the cuff  1106  are attached to one another about the circumference of the tube  1500  as modified. The base stitching  1816  secures the insertable cuff element  1308  inside the cuff  1106  in those embodiments that provide the insertable cuff element  1308 . 
     Further with reference to the stitching operation, at each of the at least one opening  1806 ,  1808  (e.g., at each pair of openings  1806 ,  1808  or at each opening  1806  if only one opening is provided), side stitchings  1818 ,  1820  are stitched through the first and second portions  1810 ,  1812  of the pocket band  1802  to form each of the pockets  1202 . The pocket band  1802  can be considered the pocket band  1201  of  FIG. 12 . The side stitchings  1818 ,  1820  can extend from about the base stitching  1816  partially towards the fold  1804  and can be angled with respect to one another in order to approximate the protective insert  204 . 
       FIG. 19  illustrates a third folding operation shown along the cross-section of the example tube  1500  to form the cuff  106  of the example protective headwear  102  of  FIG. 1 . More specifically, the cuff  106  can be folded over the body  104  at the fold  1604 . This folding operation is optional, as the cuff  106  can remain un-cuffed. Moreover, if the cuff  106  is omitted, the third folding operation is inapplicable. 
     Similarly in relation to the protective headwear  1102  of  FIG. 11 , the cuff  1106  can be folded over the body  1104  at the fold  1814 . Again, this folding operation is optional, as the cuff  1106  can remain un-cuffed. Moreover, if the cuff  1106  is omitted, the third folding operation is inapplicable 
       FIG. 20  illustrates a crown forming operation. More specifically, the edge  1510  is cut about the circumference of the tube  1500  from the edge  1510  toward the edge  1508  and access material (e.g., triangular portions) is removed to reduce the circumference of the tube  1500 . The remaining material is stitched at stitchings  2002  such that a crown  206  can be formed to complete the protective headwear  102  of  FIG. 1 . 
     Similarly in relation to the protective headwear  1102  of  FIG. 11 , the edge  1510  is cut about the circumference of the tube  1500  as modified from the edge  1510  toward the fold  1604  ( FIG. 16 ) and access material (e.g., triangular portions) is removed to reduce the circumference of the tube  1500 . The remaining material is stitched at stitchings  2002  such that a crown  1216  can be formed to complete the protective headwear  1102  of  FIG. 11 . 
     As described herein, the pocket band  201 ,  1201  can have a gradually-reduced circumference along its height toward the apex or crown  206 ,  1216 , such that improved form-fit and aesthetic look of the headwear  102 ,  1102  with respect to the head of the person  100  can be provided. The reduced or tapered circumference of the pocket band  201 ,  1201  conforms the protective inserts  204  to the head of the person  100  and prevents the protective inserts  204  from visibly pressing against or bulging out with respect to the body  104 ,  1104  of the headwear  102 ,  1102 . 
       FIG. 21  illustrates a person  100  wearing an example protective headwear  2102  in accordance with a third embodiment. The protective headwear  2102  is configured to provide a combination of a significant protective function in an aesthetic form-factor, which improves desirability for wearing the protective headwear  2102 . More superficially, the protective headwear  2102  provides the appearance of an aesthetic stretchable hat, while at the same time providing a significant protective function, which encourages the use of the protective headwear  2102  and reduces the potential for head injuries. 
     The protective headwear  2102  can be made from manmade/synthetic materials, natural materials, and/or blended combinations thereof. For example, wool, cotton, acrylic, nylon, other natural/synthetic materials, and combinations thereof can be used. The protective headwear  2102  is shown to include a body  2104  and a cuff  2106 . The cuff  2106  can be formed by cuffing or rolling an end portion of the body  2104  one or more times to the interior of the body  2104  to a thickness that approximates a thickness of the pocket band and protective insert(s) as will be described in greater detail below. 
     Accordingly, the body  2104  is configured to fit precisely and aesthetically over a person&#39;s head and to provide a protective function against head injury resulting from activities in which the person  100  engages. The activities for which the protective headwear  2102  will find implementation can include, for example, rollerblading, biking, hiking, skateboarding, touch football, soccer, field hockey, girls lacrosse, rock climbing, skiing, snowboarding, and ice-skating, as well as other sports and activities as described herein. 
       FIG. 22  illustrates the construction of the example protective headwear  2102  of  FIG. 21 . The protective headwear  2102  includes a pocket band  2201  and a plurality of protective inserts  204 . In this third embodiment, the pocket band  2201  can be provided (e.g., weaved) separately from the headwear  2102  and then attached (e.g., stitched) to the protective headwear  2102 . 
     Moreover, in various other embodiments the pocket band  2201  can be manufactured or provided as a liner, for example, which can remain separate from the protective headwear  1102 , such that the protective headwear  2102  can be completed when the protective headwear  1102  (or another cap, hat or the like) is worn over the combination of the liner (e.g., pocket band  2201 ) and the protective inserts  204 . 
     Now with further reference to  FIG. 22 , the pocket band  2201  is disposed about at least a portion of the interior of the protective headwear  2102  and is configured to receive and retain the protective inserts  204  in a predetermined configuration that provides a protective function to the person&#39;s head when the person  100  wears the protective headwear  2102 . The pocket band  2201  extends from the base stitching  2210  of the protective headwear  2102  towards the apex or crown  2212  of the protective headwear  2102  such that the protective function can be provided to the head of the person  100 . The protective headwear  2102 , and more particularly the pocket band  2201  coupled with protective inserts  204 , is configured to at least partially or fully cover the frontal, parietal, temporal and occipital part of the person&#39;s head. 
     Moreover, the pocket band  2201  provides a gradually reduced or tapered circumference along a portion of its height toward the apex or crown  2212 , such that improved form-fit and aesthetic look of the headwear  2102  with respect to the head of the person  100  can be provided. The reduced or tapered circumference of the pocket band  2201  conforms the protective inserts  204  to the head of the person  100  and prevents the protective inserts  204  from visibly pressing against or bulging out with respect to the body  2104  of the headwear  2102 . 
     The pocket band  2201  includes a plurality of pockets  2202 , each of which is defined by the side stitchings  2206 ,  2208  and the base stitching  2210 . The construction of the side stitchings  2206 ,  2208  will be explained in greater detail below. Each of the pockets  2202  is configured (e.g., sized and dimensioned) to receive and retain a respective protective insert  204 , such that the plurality of protective inserts  204  can be disposed in the predetermined configuration in the pocket band  2201  of the protective headwear  2102 . In some embodiments, six (6) pockets  2202  are provided in the pocket band  2201 . In other embodiments, there can be four (4) to twelve (12) pockets  2202 . Fewer or greater number of pockets  2202  can be provided in alternate embodiments. 
     The plurality of pockets  2202  are disposed adjacently about the pocket band  2201  such that the protective inserts  204  can be adjacently disposed (e.g., one next to the other), providing an almost continuous protective function about the protective headwear  2102 . In some embodiments, the pockets  2202  can be equidistantly disposed about the pocket band  2201 . In other embodiments, the pockets  2202  can be disposed at different locations about the pocket band  2201  based on the size and dimension of the respective protective inserts to be received into the pockets  2202 . 
     Each pocket  2202  includes an opening  2212  configured to receive the protective insert  204  into the pocket  2202 . The opening  1212  can be disposed at a top-most extent  1214  of the pocket band  2201 . In some embodiments, a second opening can be provided in each pocket  2202  disposed at distance above the base stitching  2210  and below the opening  2212 . The second opening can be approximately the same or smaller than opening  2212 . This distance can be varied along the height of the pocket band  2201 . The second opening can be offset from the top-most extent  1214  of the pocket band  2201 , to either the front or the back of the pocket band  2201 . 
     The openings  2212  are defined by the side stitching  2206 ,  2208 . The openings  2212  (and the second openings) are stretchable in order to receive and retain the protective inserts  204  in the pockets  2202  of the pocket band  2201 . The openings  2212  can be formed to be more (or less) stretchable than the second openings. 
     The side stitchings  2206 ,  2208  of each pocket  2202  extend approximately from the base stitching  2210  and along the height of the pocket band  1201  towards the apex or crown  2216  of the protective headwear  2102 . In other embodiments, the side stitchings  2206 ,  2208  can extend partially or fully to the top-most extent  2214  of the pocket band  2201 . 
     Each of the side stitchings  2206 ,  2208  is formed by defining a v-shaped pattern disposed at an offset from a lower-most extent (not shown) of the pocket band  2201  toward the top-most extent  2214 . Each of the stitchings  2206 ,  2208  thus secures respective sides of the v-shaped pattern to each other, generating triangular excised portions (not shown) that gradually reduce or taper the circumference of the pocket band  2201  along its height toward the apex or crown  2212 , such that improved form-fit and aesthetic look of the headwear  2102  with respect to the head of the person  100  can be provided. 
     As a result, the side stitchings  2206 ,  2208  are approximately angled towards one another and towards the apex or crown  1216  of the protective headwear  2102 . More specifically, the stitchings  2206 ,  2208  can be angled to approximate and accommodate the angulation of each protective insert  204 , such that the plural protective inserts  204  can be retained in a predetermined configuration with respect to one another in the respective pockets  2202  and can provide an almost continuous protective function and can conform to the person&#39;s head when the person  100  wears the protective headwear  2102 . 
     The base stitching  2210  (z-stitch pattern or anther stitch pattern) extends along the circumference of the pocket band  2201 . The base stitching  1210  is configured to secure a portion of the pocket band  2201  that extends from its lower-most extent (not shown) to about the side stitchings  2206 ,  2208  to the interior of the protective headwear  2102  as described in greater detail below. The base stitching  2210  is further configured to provide a base or seat for each of the protective inserts  204 , approximating and accommodating the base of each protective insert  204 , such that the plural protective inserts  204  can be retained in a predetermined configuration with respect to one another in the respective pockets  2202  and can provide an almost continuous protective function to the person&#39;s head when the person  100  wears the protective headwear  2102 . 
     The protective inserts  204  are configured to be disposed adjacently to one another in the respective pockets  2202  of the pocket band  2201 , providing an almost continuous protective function about the protective headwear  2102 . The protective inserts  204  are independently situated or disposed in the respective pockets  2202  of the pocket band  2201  and can conform to the contours of the person&#39;s head by the gradually reduced or tapered circumference of the pocket band  2201  and as the protective headwear  1102  stretches about the head of the person  100 . 
     The protective inserts  204  are described in greater detail with reference to  FIGS. 4-6  hereinabove. In some embodiments, six (6) protective inserts  204  can be provided. In other embodiments, there can be four (4) to twelve (12) protective inserts  204 . Fewer or greater number of protective inserts  204  can be provided in different embodiments based on the number of pockets  2202 . 
     As described hereinabove, the protective inserts  204  can also include adhesive layers  208  to enable the protective inserts  208  to be removeably secured in the pocket band  2201  of headwear  2102  or on the interior of other headwear that may not be provided with the pocket band  2201 . 
       FIG. 23  illustrates the construction of the example pocket band  2201  in the protective headwear  2102  illustrated in  FIG. 22 . 
     The pocket band  2201  has a first circumference  2302  and a second smaller circumference  2304 . The first circumference is about the circumference of the opening  2312  in the body  2104  of protective headwear  2102  (e.g., about 23 inches). The second circumference  2304  is approximately the circumference of the body  2104  about the apex or crown  2212  of the protective headwear  2102  (e.g., about 15 inches). The first and second circumferences  2302 ,  2304  can have different dimensions and proportions to one another for variously-sized heads. 
     The pocket band  2201  includes a first portion  2306  having the first circumference  2302  and a second portion  2310  having a gradually-reduced circumference extending from the first circumference  2302  to the smaller second circumference  2304  along the height of the second portion  2310 . The overall height of the pocket band  2201  is approximately 4.5 inches, with the first portion  2306  being about 0.5 inches and the second portion  2310  being about 4.0 inches. The gradually-reduced circumference can be obtained by defining and stitching v-shaped patterns about the pocket band  2201  via side stitchings  2206 ,  2208 . Specifically, each of the stitchings  2206 ,  2208  secures respective sides of the v-shaped pattern to each other, generating triangular excised portions  2308  that gradually reduce or taper the circumference of the pocket band  2201  along the height of the second portion  2310  toward the apex or crown  2212 . The gradation of the reduction in the circumferences  2302 ,  2304  can be achieved by selection of the width and height of the v-shaped pattern. 
     The cuff  2106  (shown in  FIGS. 21 and 22 ) can be formed by cuffing or rolling an end portion of the body  2104  (illustrated by the arrows) one or more times to the interior of the body  2104  to a thickness that approximates a combined thickness of the pocket band  2201  and protective insert(s)  204 . After the cuff  2106  is formed, the first portion  2306  of the pocket band  2201  is inserted or disposed between the cuff  2106  and the body  2104  to a depth such that the cuff  2106  is disposed over the pocket band  2201  to approximately the stitchings  2206 ,  2208 . Thereafter, the base stitching  2210  is applied to secure the pocket band  2201  and the cuff  2106  to the body  2104 . 
       FIG. 24  illustrates the construction of an example pocket  2202  in the pocket band  2201  of the protective headwear of  FIG. 21 . 
     The pocket band  2201  can be formed by folding a material having a first end  2402  and a second end  2404  in half about a fold or crease  2406 . The material can be a sheet having a length (e.g., about 23 inches) and a width (e.g., about 9.0 inches), or the material can be a continuous tube having a circumference of 23 inches and a height of (e.g., about 4.5 inches). The material can be a stretchable or elastic woven fabric (thread), or other conventional and stretchable material. 
     Furthermore, the pockets  2212  can be formed by defining v-shaped patterns about the pocket band  2201  and securing respective sides of the v-shaped patterns to each other via side stitchings  2206 ,  2208 . 
     As illustrated in  FIG. 24 , section  2306  has the first circumference  2302  and section  2310  has a gradually reduced circumference extending along the height of section  2310  to the second circumference  2304 . The triangular excised portions  2308  gradually reduce the circumference of the second section  2310 , and can conform the protective inserts  204  to the head of the person  100  to prevent the protective inserts  204  from visibly pressing against or bulging out with respect to the body  2104  of the headwear  2102 . 
       FIG. 25  illustrates the protective insert  204  retained in the example pocket  2202  of the pocket band  2201  illustrated in  FIG. 24 . 
     As illustrated, the side stitchings  2206 ,  2208  conform the shape of pocket  2202  to the shape of the protective insert  204 , as well as conforming the shapes of the pocket band  2201  to the shape of the head of the person  100  and the shape of protective headwear  2102  toward its apex or crown  2212  (shown in  FIG. 23 ). The adhesive layer  208  illustrated in  FIG. 22 , if provided atop a portion of the protective insert  204  that is received in the pocket  2202 , can enable the protective insert  204  to be removeably secured in relation to the pocket band  2201 . 
       FIG. 26  illustrates a cross-section of the example protective headwear  2102  of  FIG. 21 . 
     The pocket band  2201  can be weaved in a first weaving process on a loom or another automated weaving machine, and can be weaved from a thread and/or weave of a second thickness  2604 . 
     The body  2104  and cuff  2106  can be weaved in a second weaving process on a loom or another automated weaving machine, and the pocket band  2201  can then be attached to the body  2104  and cuff  1106  via base stitching  2210 . In some embodiments, a separate insertable cuff element  2606  (e.g., made of foam rubber, or other material) that is pliable and lightweight can be incorporated inside of and along the circumference of the cuff  2106 . The thickness, height and diameter of the cuff element  2606  can vary based on dimensions of the cuff  2106  of the headwear  2102 . The base stitching  2210  secures the insertable cuff element  2606  inside the cuff  106  in those embodiments that provide the insertable cuff element  2606 . 
     The first and second weaving processes can be contemporaneous, sequential or can be performed at various times. The body  2104  and cuff  2106  of the protective headwear  2102  can be weaved from a thread and/or weave of a first thickness  2602 . 
     The second thickness  2604  can be reduced from the first thickness  2602  (e.g., approximately by half or smaller from the first thickness) such that sufficient space can be provided in the pocket  2202  of the pocket band  2201  to receive a protective insert  204 , providing an aesthetic, comfortable and inexpensive form-factor that can result in increased desirability and usability of protective headwear  2102  to mitigate and/or eliminate head injuries. The first and second thicknesses  2602 ,  2604  can be same as or different than the thickness described herein in relation to other embodiments. 
     After the second weaving process, the pocket band  2201  is attached or secured by second portion  2306  between cuff  2106  and body  2104  to the protective headwear  2102  to form the pocket band  2201 , such that the protective headwear  2102  can receive and retain plural protective inserts  204  in the pockets  2202  of the pocket band  2201 . 
     As illustrated, the pocket band  2201  is free floating with respect to the body  2104  of the protective headwear  2102 , such that the pocket band  2201  can provide application-specific or precise fit and positioning of plural protective inserts  204  for various head sizes to effectively reduce and/or eliminate head injuries. 
     As further illustrated, the second thickness  2604  can be reduced from the first thickness  2602  such that sufficient space can be provided in the pocket  2202  of the pocket band  2201  to receive a protective insert  204 , providing an aesthetic, comfortable and inexpensive form-factor that can result in increased desirability and usability of protective headwear  2102  to mitigate and/or eliminate head injuries. 
     It is noted that the triangular excise portions  2308  is shown unfolded for illustration purposes, but in operation the excise portions  2308  would fold to one side or another such that the pocket  2202  (and more particularly the pocket band  2201 ) can be disposed flush to the body  2104 . 
       FIG. 27  illustrates a person  100  wearing the protective headwear  2102  of  FIG. 21  cutaway to reveal the protective insert  204  retained by a pocket band  2201  in relation to the body  2104  and the cuff  2106 . In some embodiment, the cuff  2106  can incorporate insertable cuff element  2606 . 
     Plural protective inserts  204  are secured by the pocket band  2201 —and more particularly, by the respective pockets  2202  of the pocket band  2201 —around the head of the person  100  and conform or contour to the head of the person  100 , providing a protective function to the frontal, parietal, temporal and occipital parts of the person&#39;s head. 
     The protective inserts  204  provide an almost continuous protective function amongst and between the protective inserts  204 , about the circumference of the protective band  2201  and through to the apex or crown  2212  of the protective headwear  2102 . 
       FIG. 28  illustrates a person  100  wearing an example protective headwear  2802  in accordance with a fourth embodiment, cutaway to reveal the protective insert  204  retained by a pocket band  2201  in relation to the body  2804  and the band  2806 . 
     The protective headwear  2102  is configured to provide a combination of a significant protective function in an aesthetic form-factor, which improves desirability for wearing the protective headwear  2102 . More superficially, the protective headwear  2802  provides the appearance of an aesthetic baseball cap, while at the same time providing a significant protective function, which encourages the use of the protective headwear  2802  and reduces the potential for head injuries. 
     The protective headwear  2802  can be made from manmade/synthetic materials, natural materials, and/or blended combinations thereof. For example, wool, cotton, acrylic, nylon, other natural/synthetic materials, and combinations thereof can be used. The protective headwear  2802  is shown to include a body  2804 , band  2806  (shown in  FIG. 29 ) and visor  2810 . In some embodiments, the body can be made panels  2808  secured (e.g., stitched) together. A button can be provided at the apex or crown  2812  of the protective headwear  2802 , over the join between the panels  2808 . Alternative conventional or to be developed designs of the panels  2808  can be used. 
     The band  2806  (shown in  FIG. 29 ) extends along the interior lower portion of the body  2804 . The band  2806  can be stretchable or elastic. The first portion  2306  of the pocket band  2201  is inserted or disposed between the band  2806  and the body  2804  to a depth such that the band  2806  is disposed over the pocket band  2201  to approximately the stitchings  2206 ,  2208 . Thereafter, base stitching  2904  (shown in  FIG. 29 ) is applied to secure the pocket band  2201  and the band  2806  to the body  2804 . 
     Accordingly, the body  2804  is configured to fit precisely and aesthetically over a person&#39;s head and to provide a protective function against head injury resulting from activities in which the person  100  engages. The activities for which the protective headwear  2102  will find implementation can include, for example, rollerblading, biking, hiking, skateboarding, touch football, soccer, field hockey, girls lacrosse, rock climbing, skiing, snowboarding, ice-skating, and baseball, as well as other sports and activities as described herein. 
       FIG. 29  illustrates a cross-section of the example protective headwear  2802  of  FIG. 28  with the protective insert  204  disposed in the pocket  2202 . 
     As illustrated, base stitching  2904  provides a base to retain the protective insert  204  in the pocket  2202 . As described previously herein, the protective insert  204  is inserted into the pocket  2202  of the pocket band  2201  through either the opening  2212 . 
     The openings  2212  are stretchable to receive the protective inserts  204  into respective pockets  2202  (e.g., based on the stretchable material from which the pocket band  2201  is made). Accordingly, once the protective inserts  204  are received into the pockets  2202 , the opening  2212  can contour about the approximately triangular shape of the protective insert  204  to retain or secure the protective insert  204  in the pockets  2202 . 
     As further illustrated, the pocket band  2201  with the inserted protective inserts  204  is free floating with respect to the body  2104  of the protective headwear  2802 , such that the pocket band  2201  can provide application-specific or precise fit and positioning of the plural protective inserts  204  for various head sizes (e.g., such as the head  2902  of the person  100 ) to effectively reduce and/or eliminate head injuries. 
     Moreover, one or more stitchings  2904  can be used to secure the pocket band  2201  between the body  2804  and the band  2806  of the protective headwear  2802 . 
     Thus, a form-fitting protective headwear and a method of manufacturing the form-fitting protective headwear have been described. Although specific example embodiments have been described, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention. 
     Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. The accompanying drawings that form a part hereof, show by way of illustration, and not of limitation, specific embodiments in which the subject matter may be practiced. The embodiments shown are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this application. 
     The foregoing detailed description, therefore, is not to be taken in a limiting sense, and the scope of various embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled. 
     Although specific embodiments have been shown and described herein, it should be appreciated that any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This application is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description. 
     The Abstract is provided to comply with 37 C.F.R. §1.72(b) and will allow the reader to quickly ascertain the nature of the technical disclosure of this application. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 
     In the foregoing detailed description, various features may be grouped together in a single embodiment for the purpose of streamlining the disclosure of this application. This method of disclosure is not to be interpreted as reflecting that the claimed embodiments have more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. 
     Moreover, it is contemplated that the features or components of various embodiments described herein can be combined into different combinations that are not explicitly enumerated in the foregoing detailed description and that such combinations can similarly stand on their own as separate example embodiments that can be claimed.