Patent Description:
Serious head injuries, such as traumatic brain injuries, occur in traffic, in the workplace and during sports activities. There is still an unacceptable number of head injuries worldwide. There is a need for an improved helmet, in particular a helmet that absorbs oblique impacts, that is, impacts that are not perpendicular to the surface of the helmet. Thus, it would be advantageous to prevent traumatic brain injuries by an improved head worn device.

Traumatic brain injury may lead to serious injuries or death. Traumatic brain injury in the elderly is often caused by falling. The incidence is about <NUM> cases per <NUM><NUM> persons per year, causing great stress on the healthcare system.

It would be advantageous to prevent traumatic brain injury caused by falling.

<CIT> discloses a headband that can be used for preventing head injuries, where the head-band comprises a shock-absorbing pad comprising outward-extending shock-absorbing structures.

Hence there is need for an improved material that absorbs shocks.

In a first aspect of the invention there is provided soft head-worn item comprising an elastomeric sheet with a thickness of from <NUM> to <NUM>, the elastomeric sheet having a first side and a second side, where the first side has a plurality of deformable support members where the support members have a cavity with an opening towards the second side of the elastomeric sheet, or where the support members have an aperture from the fist side to the second side, and where the hardness of the material of the elastomeric sheet is from <NUM> Shore A to <NUM> Shore A, where the soft head worn device comprises an inner layer that is arranged to rest against the head of the user and a mesh layer in contact with the elastomeric layer between the elastomeric sheet and the inner layer where the mesh layer is provided in contact with the support members.

Further aspects and embodiments are provided in the dependant claims.

The accompanying drawings form a part of the specification and schematically illustrate preferred embodiments of the invention, and serve to illustrate the principles of the invention.

The elastomeric sheet <NUM> may be used for a wide range of applications where it is useful to dampen shock. Examples of applications include flooring, protective clothing such as a helmet, a hat or a headband and sports equipment, for example a horseshoe, or in machinery. The claimed invention is, however, limited to a soft head-worn item.

With reference to <FIG> the elastomeric sheet <NUM> has a plurality of deformable support members <NUM> said support members <NUM> being configured to be deformed upon shock (mechanical shock). The elastomeric sheet <NUM> has first side <NUM> that has support members <NUM> and a second side <NUM> that is essentially flat.

The support members <NUM> are configured to be deformed when the elastomeric sheet <NUM> receives an impact (see below with reference to <FIG>, <NUM>-<NUM> and <NUM>-<NUM>). The main purpose of elastomeric sheet <NUM> is to provide shock absorption, that is, to absorb the energy of an impact. This is achieved by the selection of the material of elastomeric sheet <NUM> and the deformable supports members <NUM>.

The hardness of the material of the elastomeric sheet <NUM> is preferably from <NUM> Shore A to <NUM> Shore A, even more preferably from <NUM> Shore A to <NUM> Shore A, and most preferably from <NUM> Shore A to <NUM> Shore A. Permeably the elastomeric sheet <NUM> is made from one material with a defined harness, hence the hardness of the elastomeric sheet <NUM> is preferably uniform.

The elastomeric sheet <NUM> may be made from rubber or any other suitable elastomer. The elastomer may be a polymer. Suitable elastomers include various rubber materials for example: styrene butyric rubber, butyric rubber, isoprene rubber, butylic rubber, eten propene rubber, nitrilic butadiene rubber, chloroprene rubber, polyurethane rubber, acryl eten rubber and propene oxide rubber. Butyl rubber (IIR) is a preferred material.

It is preferred that the elastomeric sheet <NUM> and the support members <NUM> are essentially solid, that is that they are essentially made of a solid material. However, each of the support members <NUM> may have at least one cavity <NUM> or aperture <NUM> as shown in for example <FIG> and <FIG> and <NUM>-<NUM>. As used herein the cavity <NUM> only has an opening to one of the sides of the elastomeric sheet <NUM>, whereas an aperture <NUM> has openings towards both sides of the elastomeric sheet <NUM>.

The support members <NUM> may be arranged in any suitable pattern. Non-limiting examples of shapes and arrangements of support members <NUM> are shown in <FIG>. The support members <NUM> can have any suitable shape such as oval, circular etc. The distance between the members <NUM> may for example <NUM>-<NUM> (c/c), preferably <NUM>-<NUM>. The thickness <NUM> of the elastomeric sheet <NUM> is preferably from <NUM> - <NUM>. The height <NUM> of the support members <NUM> in relation to the total thickness <NUM> of the elastomeric sheet <NUM> may be <NUM>-<NUM> %, of the total thickness of the elastomeric layer <NUM>.

It is preferred that the support members <NUM> are narrowing towards the tip of the support member <NUM>. Hence the base of the support member <NUM> is preferably wider than the tip. The support members <NUM> have an aperture <NUM> from the fist side to the second side or a cavity <NUM> which is open to the second side. The purpose of aperture <NUM> or cavity <NUM> is to provide springiness to the elastomeric sheet <NUM> and to reduce weight.

The elastomeric sheet <NUM> may be used in various applications where it is useful to dampen shock such as in clothing, sports equipment, flooring, helmet or machinery. The claimed invention is, however, limited to a soft head-worn item.

With reference to <FIG>, which shows a preferred embodiment of the elastomeric sheet <NUM>, the support members <NUM> are preferably square, and pyramid shaped and arranged in a matrix pattern. The top of the pyramid-shaped support members <NUM> may have a flat surface <NUM>. The pyramid shaped support members may have four sides, thus having a square base as show in the <FIG> but they may also have three sides (the base of the support member is then triangular). The angle of the side of the pyramid-shaped support members may be from <NUM>° to <NUM>° in relation the second side <NUM>.

The height <NUM> of the support members <NUM> in relation to the total thickness <NUM> of the elastomeric sheet <NUM> may be <NUM>-<NUM> %, more preferably <NUM>% -<NUM>%, more preferably <NUM>-<NUM> % of the total thickness of the elastomeric layer <NUM>. The thickness <NUM> of the elastomeric sheet <NUM> is preferably from <NUM> to <NUM>, more preferably <NUM> to <NUM> and most preferably from <NUM> to <NUM>. For example, the total thickness <NUM> of the elastomeric layer <NUM> may be from <NUM> to <NUM> and the height <NUM> of the support members <NUM> may be from to <NUM> to <NUM>.

The support members <NUM> may be essentially solid as shown in <FIG>. It is preferred that the otherwise solid support members <NUM> have a cavity <NUM>. The cavity <NUM> is preferably located in the middle of the support member (<FIG>) when the support member <NUM> is observed from direction of arrow <NUM> in <FIG> (central location of cavity <NUM>). The cavity <NUM> may have any suitable shape but is preferably cylinder shaped.

The cavity <NUM> has at least one opening <NUM> on the first side <NUM> or the second side <NUM>, and in <FIG> it is shown how the cavity <NUM> has one opening <NUM> on the second side <NUM>. The main direction of cavity <NUM> is preferably perpendicular to the main plane of the elastomeric sheet <NUM>. The cavity <NUM> may be in the form of a cylinder-shaped cavity <NUM> that opens towards the second side <NUM> as shown in <FIG>. The width <NUM> of the cavity is preferably the same along the height of the support member <NUM> as shown in <FIG>. The diameter of the cavity when it is cylinder shaped may be from <NUM> - <NUM>. The depth of the cavity may preferably be from <NUM> to <NUM>.

The volume of the cavity <NUM> is preferably at most <NUM> %, more preferably at most <NUM> % and even more preferably at most <NUM> % of the volume of the support member <NUM>. The volume of the support member is calculated as the part of the support member <NUM> that is indicated by arrow <NUM>.

The head worn device may be a helmet, a hat or a head band. The claimed invention is, however, limited to a soft head-worn item.

The head worn device can be worn by a user to protect the user during sports activities (biking, skiing, riding, for example), in the workplace (such as at construction sites) or in traffic (such as by motorcyclists), or otherwise. When the head worn device is a hat or a headband it may particularly be useful in everyday use by the elderly, or by persons with poor balance.

The head worn device will now be described in more detail mainly in reference to a helmet. However, it is noted that the claims are directed to a soft head worn device and not a helmet.

shows a head worn device <NUM> which is a helmet, which does not form part of the claimed invention. The helmet comprises outer layer <NUM>, shock absorbing layer <NUM> and optional inner layer <NUM>. It should be observed that, for clarity, the thickness of the layers is exaggerated in <FIG>. The outer layer <NUM> and the inner layer <NUM> are referred to herein as "second layer".

The outer layer <NUM> is preferably in the form of a hard shell. The outer layer <NUM> may be formed in a polymer material such as for example polycarbonate, polyvinylchloride or ABS and may be reinforced with fibers such as carbon fibers or Kevlar™. The outer layer <NUM> is preferably thinner than the shock-absorbing layer <NUM>. The outer layer <NUM> may serve the purpose of distributing the shock of an impact to shock absorbing layer <NUM>. The outer layer <NUM> may also provide protection against perforation, such as cuts.

The optional inner layer <NUM> is suitable for resting against the head of a user and is preferably comfortable for the user. The inner layer <NUM> may be adjustable in order to provide a snug fit on the head of the user. Hence inner layer <NUM> may be loosely fitted to shock absorbing layer <NUM> in order to be adjustable to the head of the user. Inner layer <NUM> may comprise an adjustable band that is circumferential in relation to the head of the user, in order to adjust the helmet to the head of the user.

The helmet may preferably have an attachment device for attaching the helmet to the head. The attachment device is preferably a chin strap.

The outer layer <NUM>, the inner layer <NUM> and the shock absorbing <NUM> layer are preferably attached to each other. One or more layers may for example be glued together, in particular outer layer <NUM> and shock absorbing layer <NUM>. The outer layer <NUM> is preferably thinner than the shock-absorbing layer <NUM> and may have a thickness of approximately <NUM>-<NUM> or <NUM>-<NUM>. The inner layer <NUM> is also preferably thinner than the shock-absorbing layer <NUM> and may have a thickness of <NUM> - <NUM> or <NUM>-<NUM>.

It should be noted that each layer of the helmet may comprise additional layers providing different functions as strength, shock, water proofing, insulation, colour, attachment between layers (such as glue) or adjustability of helmet.

The shock absorbing layer <NUM> comprises at least one layer of an elastomeric sheet <NUM>.

The shock absorbing layer <NUM> preferably comprises one or two or more of the elastomeric sheets <NUM> as described below. The thickness of the shock absorbing layer <NUM> is preferably from <NUM>-<NUM>, more preferably from <NUM>-<NUM> and even more preferably from <NUM>-<NUM>.

In a preferred example the elastomeric sheet <NUM> of the helmet has the shape and dimensions described with reference to <FIG> (pyramid shaped supports <NUM> with cavity <NUM>). An example of such a helmet is shown in <FIG>.

<FIG> shows one embodiment of the support members <NUM> where the support members have a square configuration (grooves meet at <NUM>° angles) and have apertures <NUM>.

In an alternative embodiment and with reference to <FIG> the height of the support members <NUM> in relation to the total thickness of the elastomeric sheet <NUM> may be <NUM>% -<NUM>%, more preferably <NUM>-<NUM> % of the total thickness of the elastomer layer <NUM>.

With reference to <FIG>, the support members <NUM> may for example have the shape of members separated by grooves <NUM> in a criss-cross pattern. The grooves <NUM> may have a depth which is <NUM> % to <NUM> %, more preferably <NUM>% -<NUM>% of the total thickness of the elastomeric sheet <NUM>. The grooves <NUM> may for example have a depth of for example <NUM>-<NUM>. The grooves <NUM> may have a width of <NUM>-<NUM>, preferably <NUM>-<NUM>. The walls <NUM> of the grooves may be slanted as shown in <FIG> such that the profile of the grooves <NUM> is conical. The grooves <NUM> may have a flat or a pointed bottom <NUM> (where a pointed bottom is shown in <FIG>.

The thickness of the elastomeric sheet <NUM> shown in <FIG> is preferably from <NUM> to <NUM>, more preferably <NUM>-<NUM>, even more preferably <NUM>-<NUM>. The elastomeric sheet <NUM> is preferably provided with through holes or apertures, hereafter referred to as apertures <NUM>. The apertures <NUM> go from the first side <NUM> of the elastomeric sheet <NUM> to the second side <NUM> of the elastomeric sheet <NUM>. Apertures <NUM> are preferably perpendicular to the elastomeric sheet <NUM>. The apertures <NUM> may have a diameter of from <NUM>-<NUM> and may be spaced for example <NUM>-<NUM> (c/c), preferably <NUM>-<NUM> apart. The shortest distance between the holes may be <NUM>-<NUM>. The apertures <NUM> may be placed in the centre of the support members <NUM>, as shown in Figs. <NUM>-<NUM>.

<FIG> show how the elastomeric sheet <NUM> of <FIG> behaves upon receiving an oblique shock (<FIG>) or a translational shock (<FIG>) in a test set-up. The sheet <NUM> is covered by a shock-distributing layer which may mimic the behaviour of outer layer <NUM> of helmet <NUM> in that it distributes the shock to the elastomeric sheet <NUM>. The elastomeric sheet <NUM> is placed on a hard surface <NUM> and a weight is allowed to fall onto the surface <NUM> of the sheet <NUM>. The arrows indicate the direction of impact on the shock-distributing layer <NUM> of the sheet <NUM>.

<FIG> show cross sections of a head worn device <NUM>. <FIG> show embodiments with one elastomeric sheet <NUM>, where the support members <NUM> of the elastomeric sheet points towards the inner layer <NUM> and the outer layer <NUM>, respectively.

In <FIG>, two elastomeric sheets 2a, 2b are arranged with the supporting members <NUM> pointing towards each other thereby forming a shock-absorbing layer <NUM> between outer layer <NUM> and inner layer <NUM>.

<FIG> shows an embodiment double layer of the material of <FIG> where the support members are pointing towards each other. It may be preferred that the tips of the support members <NUM> (for example flat surface <NUM>) rests against each other.

In <FIG> the support members <NUM> are pointing in opposite directions, as one set of support members <NUM> point towards the inner layer <NUM> and one set of support members <NUM> point out towards the outer layer <NUM>. With reference to <FIG> it should be noted that the support members <NUM> of elastomeric sheets 2a, 2b may also point in the same direction. When two or more elastomeric layers 2a, 2b are used they may optionally be attached to each first or second surfaces <NUM>,<NUM>, for example with glue. Hence the plurality of elastomeric layers 2a, 2b may form a sandwich material. The plurality of elastomeric layers 2a, 2b may be essentially immobile in relation to each other.

When the helmet does not have inner layer <NUM> the shock absorbing layer <NUM> will be in be in contact with the head of the user. Hence in certain examples the support members <NUM> may be in contact with the head of the user. The shock absorbing layer <NUM> comprises a mesh layer <NUM> in contact with the elastomeric layer. Hence the elastomeric layer <NUM> is combined with a mesh layer <NUM>, preferably a textile mesh. The mesh layer <NUM> is preferably one single mesh layer <NUM>. The mesh layer <NUM> may be able to slide against elastomeric layer <NUM>. The mesh layer <NUM> may have thickness of from <NUM> to <NUM>, more preferably from <NUM> to <NUM>. The mesh layer <NUM> has the advantage of absorbing oblique shocks when combined with elastomeric layer <NUM>. The mesh layer <NUM> may be pliable. The mesh <NUM> may be stretchable. The mesh <NUM> may be made from any suitable material such as nylon or polyester. The mesh <NUM> may be produced using any suitable technology such as extrusion, weaving or knitting. The size of the openings <NUM> in the mesh may be for example <NUM> to <NUM>. Hence the individual strings in the mesh <NUM> may be separated by at most <NUM> to <NUM>. The openings <NUM> in the mesh <NUM> may for example be rhomboids or rectangles or quadrats. An example of a rhomboid mesh material is shown in <FIG>. The mesh layer <NUM> preferably has low friction towards the elastomeric layer <NUM>. The mesh <NUM> may be a mesh where the mesh material <NUM> (for example strings that form the mesh) covers at least <NUM>%, more preferably at least <NUM> % and most preferably at least <NUM> % of the surface of the mesh material. <FIG> shows an example of a suitable mesh material where mesh material covers <NUM> at least <NUM>% or more of the surface of the mesh material. Hence the openings <NUM> are at most <NUM> % of the surface of the mesh material.

The mesh may provide slidability in relation to elastomeric layer <NUM>. The mesh layer <NUM> is preferably arranged between the support members <NUM> and the head of the user of the head-worn device <NUM>.

The mesh layer <NUM> may be used for example together with a helmet <NUM> or other head worn device or other type of protective covering. The combination of the elastomeric layer with the mesh layer <NUM> is useful in any type of wearable shock protecting items such as for example helmets, hat, head band <NUM>, shoulder pads, hip guards, or back protection items.

The head worn device <NUM> according to the claimed invention is a soft head-worn item such as a hat or a head band <NUM>.

The term "soft head-worn item" refers to an item suitable to be worn on the head. An example of a head band <NUM> is shown in <FIG>. A soft head worn device differs from a helmet in that the outer layer <NUM> is not hard as in the case of a helmet. Also, the soft head-worn device may lack an attachment device such as a chin strap. Instead, the soft head-worn item typically attach to the head by having a snug fit. A soft head-worn item, in particular a head band <NUM>, may be more comfortable than a helmet for use among elderly in everyday situations.

The soft head-worn item <NUM> comprises at least one elastomeric sheet <NUM>. There may be one or more sheets <NUM>, and the combined thickness of the sheets <NUM> is preferably from <NUM> to <NUM>, i.e. somewhat slimmer than in the case of a helmet. The elastomeric layer <NUM> may for example have a thickness of from <NUM> to <NUM> in the case of a hat or a head band <NUM>. But the dimensions and proportions described in relation to <FIG> may also be used. In addition, the soft head-worn item comprises at least one additional layer which may be made from for example cloth, such as wool, fleece, cotton or a synthetic polymer cloth, or other suitable material. The additional layer may be an outer soft layer <NUM> in addition to an inner layer <NUM>. The additional layer may provide heat insulation, colour or provide a comfortable feeling to the head.

In a preferred embodiment the elastomeric sheet <NUM> of the soft head worn item is as described with reference to <FIG>.

<FIG> shows a soft head worn item, in this case a head band <NUM>, that comprises an outer layer <NUM> and inner layer <NUM> band. Outer layer <NUM> and inner layer <NUM> form an outer covering <NUM> in which a strip of elastomeric sheet <NUM> is arranged. Outer layer <NUM> and inner layer <NUM> may be made from the same material (forming outer covering <NUM>) and should provide a good feel towards the head and may also have a pleasant look. Outer layer <NUM> and inner layer <NUM> may for example be made from any suitable cloth or fabric commonly used for clothing such as polar fleece (Synchilla®), nylon, wool or cotton. The elastomeric layer <NUM> is arranged with mesh layer <NUM> between elastomeric layer <NUM> and inner layer <NUM>, as shown in <FIG>.

Hence the head band <NUM> or other soft head-worn item comprises a strip of elastomeric sheet <NUM>. The strip may have a width of from <NUM> to <NUM>, for example. The head band <NUM> is configured to be worn around the circumference of the head. The strip if elastomeric layer <NUM> does not necessarily have to go around the full circumference of the head. In particular the head band may be sized and located so that it protects the posterior part of the head thereby preventing injury in a backwards fall. It is preferred that the hat or the headband <NUM> protects the forehead and posterior part of the head.

The hat and the head band <NUM> may be provided in different sizes. The size of the hat and the head band <NUM> may be adjustable, with the use of a size adjustment device. The adjustment device adjusts the circumference of the hat or the head band <NUM>. A headband <NUM> may have a holding part that goes over the top of the head, which prevents the headband from sliding down.

It is realized that everything which has been described in connection to one embodiment is fully applicable to other embodiments, as compatible. Hence, the invention is not limited to the described embodiments, but can be varied within the scope of the enclosed claims.

While the invention has been described with reference to specific exemplary embodiments, the description is in general only intended to illustrate the inventive concept and should not be taken as limiting the scope of the invention.

A material with the design of <FIG> and <NUM>-<NUM> was formed from natural rubber with various degrees of hardness. The hardness was measured using Shore A methodology. The results are shown in Table <NUM>.

A material (an elastomeric layer) was formed by using the material from Example <NUM> covered by <NUM> vinyl material.

The impact energy/acceleration was measured using a <NUM> dummy head that was allowed to fall <NUM> on to a stell plate surface covered by the material with <NUM> Shore A or a naked surface without the material. The impact was reduced with <NUM> % compared to no dampening material.

A <NUM> steel body was allowed to fall onto the <NUM> Shore A material from <NUM>. The energy was reduced with <NUM>% compared to control.

An elastomeric layer with the shape of <FIG> was formed from butyl rubber (IIR). The material had a hardness of between <NUM> and <NUM> Shore A. The total thickness of the elastomeric layer was <NUM> and the height of the support members was <NUM>.

A <NUM> dummy head containing an accelerometer was allowed to fall from <NUM> or <NUM> onto a steel plate. The sheet was attached to the dummy or the steel plate as described below. The steel plate was horizontal to achieve a straight impact or angled at <NUM>° to obtain an oblique impact. The percentage dampening in relation to using no dampening material is shown in Table <NUM>.

For head band trials a head band with outer covering, an elastomeric layer according to Example <NUM> and a pliable polymer mesh arranged between the deformable supports and the outer covering was attached to the dummy, and allowed to fall to the steel plate. A photo of the mesh material used is provided as <FIG>. The deformable supports were directed upwards, towards the dummy.

For horseshoe trials, a regular metal horseshoe with an elastomeric layer with the support members directed upwards, was attached to the <NUM> dummy and allowed to fall to the steel plate. A regular steel horseshoe was used as control.

For floor trials the dummy was allowed to fall on to the steel plate which was covered by the material covered by a vinyl upper layer. The deformable supports were directed downwards.

Table <NUM> shows percentage decrease in acceleration force compared to control.

Claim 1:
A soft head-worn item (<NUM>) comprising an elastomeric sheet (<NUM>) with a thickness of from <NUM> to <NUM>, the elastomeric sheet (<NUM>) having a first side (<NUM>) and a second side (<NUM>), where the first side (<NUM>) has a plurality of deformable support members (<NUM>) where the support members (<NUM>) have a cavity (<NUM>) with an opening towards the second side (<NUM>) of the elastomeric sheet (<NUM>), or where the support members have an aperture (<NUM>) from the fist side (<NUM>) to the second side (<NUM>), and where the hardness of the material of the elastomeric sheet (<NUM>) is from <NUM> Shore A to <NUM> Shore A, characterized in that the soft head worn device (<NUM>) comprises an inner layer (<NUM>) that is arranged to rest against the head of the user and a mesh layer (<NUM>) in contact with the elastomeric sheet (<NUM>) between the elastomeric sheet (<NUM>) and the inner layer (<NUM>) where the mesh layer (<NUM>) is provided in contact with the support members (<NUM>).