PROTECTIVE HEADBAND

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 63/715,088 filed on Nov. 1, 2024, incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The disclosure relates generally to the field of protective headgear, and more particularly, to impact-resistant padding for protective headbands.

BACKGROUND OF THE DISCLOSURE

Conventionally, participants in “contact” sports (e.g., wrestling, football, rugby) wear protective headgear or headbands to cushion the force of impacts that are regularly received during those events. In recent years, the negative health effects of the impacts to the head experienced during such contact sports, as well as “non-contact” sports such as soccer have been a matter of focus. These negative health effects can be diminished or minimized by effectively cushioning participants from the forces of impacts. Accordingly, improved structures, such as impact-resistant headbands, are desired to lessen the impact forces experienced by those participants.

SUMMARY OF THE DISCLOSURE

Aspects of the present disclosure relate to a protective headband including at least one padding layer having at least one length of material and at least one elastic connector configured to hold the shape of the at least one padding layer in a loop.

In some embodiments, the protective headband further includes at least one reinforcement layer at least partially attached to at least one surface of the at least one padding layer.

In some embodiments, the at least one padding layer comprises at least one break or gap in the layer. In some embodiments, the at least one elastic connector at least partially spans or covers the break or gap in the layer.

In some embodiments, the at least one padding layer comprises at least one expansion joint positioned at the break or gap. In some embodiments, the at least one expansion joint comprises dovetailing portions formed in the at least one padding layer.

In some embodiments, the at least one elastic connector comprises first and second elastic connectors, each at least partially spanning or covering the at least one break or gap in the layer.

In some embodiments, the protective headband further includes a cover layer at least partially surrounding the at least one padding layer, the at least one elastic connector, and the at least one reinforcement layer.

In some embodiments, the protective headband further includes at least one patch comprising at least one layer of material positioned on the cover layer.

In some embodiments, the at least one patch comprises at least one of friction features, a pattern of friction features, raised portions, directional portions, ridges, bumps, indents, and detents. In some embodiments, the at least one patch comprises a first patch and a second patch, wherein the second patch is offset on the cover layer from the first patch.

In some embodiments, at least one of the at least one padding layer, the at least one elastic connector, and the at least one reinforcement layer are configured to form one or more regions of varying elasticity around the loop.

In some embodiments, the protective headband further includes adjustment means for adjusting the size of the loop comprising at least one selected from hook and loop, strap adjuster, and buckle.

In some embodiments, the cover layer is removable from the other layers. In some embodiments, the cover layer comprises an opening for removing the other layers from the cover layer. In some embodiments, the cover layer comprises fastening means for the closing the opening comprising at least one of hook and loop, button, snap, and zipper.

In some embodiments, the at least one padding layer comprises one or more materials selected from the group consisting of: impact resistant material, elastomeric material, urethane rubbers, silicone rubbers, nitrile rubbers, butyl rubbers, acrylic rubbers, natural rubbers, styrene-butadiene rubbers, plastic, foam, open-cell foam, multi-durometer foam, memory foam, gel, and hydrogel.

In some embodiments, the at least one reinforcement layer comprises at least one of woven material, fibrous material, high tensile strength fibrous material, natural fiber, synthetic fiber, cotton fiber, elastic fiber, elastic material, inelastic material, aramid fibers, fiberglass, and Kevlar®.

In some embodiments, the cover layer comprises at least one of soft material, biocompatible material, woven material, synthetic material, natural material, cotton material, breathable material, sweat-resistant material and washable material.

In some embodiments, the material of the at least one patch comprises at least one of polymeric material, composite material, soft material, hard material, elastic material, inelastic material, silicone, gel, foam, and plastic.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure is illustrated by way of example and not limitation in the accompanying drawings, in which like references indicate similar elements, and in which:

FIG. 1 shows an exemplary protective headband in accordance with aspects of the present disclosure;

FIG. 2 shows the exemplary protective headband of FIG. 1 with a fabric cover;

FIG. 3 shows another exemplary protective headband in accordance with aspects of the present disclosure;

FIGS. 4 and 5 show another exemplary protective headband including elastic portions in accordance with aspects of the present disclosure;

FIGS. 6, 7 and 8 show various exemplary headbands in accordance with aspects of the present disclosure;

FIG. 9 shows another exemplary protective headband with soft flexible silicone strips in accordance with aspects of the present disclosure;

FIG. 10 shows an expanded gap or break in the padding layer of the protective headband of FIG. 9;

FIG. 11 shows a non-expanded gap or break in the padding layer of the protective headband of FIG. 9;

FIG. 12 shows an expanded gap or break in the padding layer of the protective headband of FIG. 9;

FIG. 13 shows another exemplary protective headband having an expansion joint in accordance with aspects of the present disclosure; and

FIGS. 14, 15 and 16 showing the testing of an exemplary protective headband on a testing rig.

DETAILED DESCRIPTION

The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described devices, systems, and methods, while eliminating, for the purpose of clarity, other aspects that may be found in typical similar devices, systems, and methods. Those of ordinary skill may recognize that other elements and/or operations may be desirable and/or necessary to implement the devices, systems, and methods described herein. But because such elements and operations are well known in the art, and because they do not facilitate a better understanding of the present disclosure, a discussion of such elements and operations may not be provided herein. However, the present disclosure is deemed to inherently include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the art.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. For example, as used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. That is, terms such as “first,” “second,” and other numerical terms, when used herein, do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the exemplary embodiments.

Exemplary embodiments of the wearable devices described herein relate to protective headbands and padding that incorporate impact-resistant materials to cushion the force of impacts to a user's head. As used herein, the term “impact-resistant” is intended to encompass any object that partially or fully lessens, diminishes, dissipates, deflects, or absorbs the mechanical force of an impact.

The exemplary protective headbands disclosed herein are particularly suitable for use by participants in athletic activities, including traditional “contact” sports, such as wrestling, American football, or rugby, where high-force impacts may be commonly experienced, as well as sports traditionally considered to be “non-contact” such as soccer where head injuries may occur. While the exemplary embodiments of the disclosure are described herein with respect to athletic activities, it will be understood that the disclosed devices are not so limited. Suitable applications for the headbands of the present disclosure also include military helmets or construction helmets. Other suitable applications will be readily understood by one of ordinary skill in the art from the description herein.

Referring now to the drawings, FIG. 1 illustrates an exemplary protective headband 100 in accordance with aspects of the present disclosure. Headband 100 may be worn by a user during an athletic activity. In some embodiments, headband 100 may be worn underneath one or more other pieces of protective headgear. As a general overview, headband 100 includes at least one padding layer 110.

In some embodiments, padding layer 110 forms the body of headband 100. In some embodiments, such as shown in FIG. 1, padding layer 110 comprises a pair of first portions 112 extending in a first direction along an axis A. Further, padding layer 110 further comprises a second portion 114 extending in the same, first direction. As shown in FIG. 1, second portion 114 is offset from and/or spaced (off-axis) from axis A. Still further, padding layer 110 comprises a pair of curved and/or angled portions 116 connecting between the first portions 112 and second portion 114. As shown in FIG. 1, angled portions 116 extend in an oblique direction relative to the first direction.

In some embodiments, padding layer 110 is formed from impact-resistant materials. For example, padding layer 110 may include at least one layer of elastomeric material. The elastomeric material may provide impact-resistance by absorbing and dissipating the force of impacts laterally along the surface of the elastomeric material. In one exemplary embodiment, padding layer 110 comprises a single layer of elastomeric material. In another exemplary embodiment, padding layer 110 comprises two or more layers of elastomeric material. Padding layer 110 may include the layers of elastomeric material directly adjacent to each other, or may include at least one reinforcement or additional layer, such as a layer of high tensile strength fibrous material between the layers of elastomeric material. The reinforcement or additional layer may be attached to padding layer 110 with any known means, including, but not limited to, adhesive, fusing, stitching, weaving, or the like. In some embodiments, only portions of the reinforcement or additional layer are attached to padding layer 110, such as only around the edges of the layer, leaving middle portions of the additional layer free to move or slide against the padding layer 110, or to expand at a different rate relative to padding layer 110 when the headband is worn. In some embodiments, padding layer 110 is attached to additional layer with stitching around the edges, and an adhesive attaching central portions of the layers.

In some embodiments, the materials and thickness of padding layer 110 can be selected such that padding layer 110 remains sufficiently flexible to allow the protective headband to maintain contact with a user's head along an entire circumference of the user's head. In an exemplary embodiment, padding layer 110 has a thickness of less than approximately 0.75 inches, 0.7 inches, 0.65 inches, 0.6 inches, 0.55 inches, 0.5 inches, 0.45 inches, 0.4 inches, 0.35 inches, 0.3 inches, 0.25 inches, 0.2 inches, 0.15 inches, 0.1 inches or 0.05 inches.

Additionally, the order of materials in padding layer 110 may be important for providing optimal protection to the user. In an exemplary embodiment in which padding layer 110 includes a layer of elastomeric material and a layer of high-tensile strength fibrous material, the layer of high-tensile strength fibrous material is positioned closer to the user than the layer of elastomeric material. This may desirably protect the layer of high-tensile strength fibrous material from rips, tears, or punctures, as it may be more susceptible to such damage than the layer of elastomeric material.

In some embodiments, headband 100 provides the greatest protection and/or user comfort when second portion 114 is positioned over the user's lower forehead during use. Accordingly, angled portions 116 are desirably sized and shaped to position second portion 114 in the optimal position during use of headband 100. In some embodiments, second portion 114 may have a width that is greater than or less than a width of the first portions 112 of padding layer 110 in order to provide greater protection to the user's forehead.

In one embodiment, angled portions 116 extend at an angle between approximately 15° and approximately 23° relative to the first direction (along which extend first portions 112). In one embodiment, angled portions 116 extend at an angle between approximately 17° and approximately 21° relative to the first direction.

In another embodiment, angled portions 116 have a length of between approximately 2-4 inches, and second portion 114 has a length of between approximately 4-7 inches. In some embodiments, the particular lengths of second portion 114 and angled portions 116 may be selected based on the size of the user's head. In some embodiments, second portion 114 is offset or spaced from the first axis A by a distance of between approximately 0.5-2.0 inches.

As shown in FIG. 1, in some embodiments second portion 114 has a substantially straight shape (i.e., is substantially parallel to axis A). However, it will be understood that the disclosed devices are not so limited. In an alternative embodiment, second portion 114 may have a substantially arcuate shape (i.e., second portion 114 may be curved toward first axis A).

FIG. 2 shows protective headband 100 with an exemplary fabric layer or cover 130 in accordance with aspects of the present disclosure. Fabric cover 130 is configured to at least partially surround padding layer 110. Fabric cover 130 may desirably provide a more comfortable feeling for the user of headband 100 than direct contact with padding layer 110.

As shown in FIG. 2, fabric cover 130 may comprise at least one attachment mechanism 132 for attaching an end of one of the first portions 112 of padding layer 110 to the end of the other first portion 112 of padding layer 110. In an exemplary embodiment, attachment mechanism 132 comprises a hook and loop fastener. Alternative attachment mechanisms will be known to those of ordinary skill in the art. Examples of such mechanisms include buttons, snaps, buckles, clasps, etc. Attachment mechanism 132 desirably enables headband 100 to be adjustable in circumference to allow headband to snugly and comfortably fit on the user's head during use.

FIG. 3 illustrates another exemplary protective headband 200 in accordance with aspects of the present disclosure. Headband 200 may be worn by a user during an athletic activity. In some embodiments, headband 200 may be worn underneath one or more other pieces of protective headgear. As a general overview, headband 200 includes a padding layer 210. In some embodiments, headband 200 includes substantially the same features of headband 100 except as described below.

As shown in FIG. 3, in some embodiments padding layer 210 comprises a pair of first arcuate portions 212, each first arcuate body portion having opposed upper and lower arcuate edges, and a second arcuate portion 214 extending between the pair of first arcuate portions 212, second arcuate portion 214 having opposed upper and lower arcuate edges. In some embodiments, second arcuate portion 214 is curved in the same direction as the pair of first arcuate portions 212 (e.g., a counter-clockwise curve from left to right in FIG. 3). In some embodiments, second arcuate portion 214 is curved in the opposite direction as the pair of first arcuate portions 212. In some embodiments, padding layer 210 may be formed from any of the impact-resistant materials described above with respect to padding layer 110.

In some embodiments, headband 200 provides the greatest protection and user comfort when second arcuate portion 214 is positioned over the user's lower forehead during use. Accordingly, the length and radius of curvature of second arcuate portion 214 can be selected to place second arcuate portion 214 in the optimal position during use of headband 200.

In one embodiment, second arcuate portion 214 has a different radius of curvature than the pair of first arcuate portions 212. For example, second arcuate portion 214 may have a radius of curvature between approximately 9-12 inches, and first arcuate portions 212 may have a radius of curvature between approximately 7-10 inches. In some embodiments, headband 200 conforms more tightly to the user's head during athletic activities than headband 100, and may increase compression on the head to prevent accidental dislodgement during athletic activities.

In some embodiments, padding layer 210 may further comprise one or more notches 216. Notches 216 can be formed at one or both ends of second arcuate portion 214. Notches 216 are formed on the inside of the curve of second arcuate portion 214 (i.e., on the top side in FIG. 3). Notches 216 desirably allow padding layer 210 to better contour to the user's head during athletic activities, thereby providing better protection and a decreased change of dislodgement.

In an exemplary embodiment, notches 216 have a triangular shape, as shown in FIG. 3. However, it will be understood to one of ordinary skill in the art that the shape of notches 216 shown in FIG. 3, is illustrative, and is not intended to be limiting. Other suitable shapes for notches 216 will be known to one of ordinary skill in the art from the description herein.

FIGS. 4 and 5 show another exemplary protective headband including elastic portions in accordance with aspects of the present disclosure. FIGS. 6, 7 and 8 show various exemplary headbands with and without fabric covers in accordance with aspects of the present disclosure.

In some embodiments, headband 300 may be worn by a user during an athletic activity. In some embodiments, headband 300 may be worn underneath one or more other pieces of protective headgear. As a general overview, headband 300 includes a padding layer 310 similar to padding layer 110 described above. It should be appreciated that any layers, features, and materials of headbands 100, 200 and 300 may be shared across the embodiments and combined in any way.

In some embodiments, padding layer 310 may comprise a single piece wrapped upon itself to form a loop with an external portion 320 at least partially overlapping an internal portion 322. In some embodiments, headband 300 includes at least one elastic connector (301, 302) configured to hold the shape of the looped headband 300. In some embodiments, elastic connectors (301, 302) provide for a universal or near-universal sizing for a large range of human heads. In some embodiments, headband padding layer 310 has a length in the range of 24.75″ to 26.75″, a width in the range of 1.875″ to 2.5″, and a thickness in the range of 375″ to 0.625″. In some embodiments, headband 300 is configured to fit a head of circumference in the range of 21.5″ to 23.5″. In some embodiments, elastic connectors (301, 302) provide suitable tension to keep the headband positioned during use.

In some embodiments, an internal elastic connector 301 extends from an end of the internal portion 322 to an interior surface of the padding layer 310 proximate to the external portion 320. In some embodiments, an external elastic connector 302 extends from an end of the external portion 320 to an exterior surface of the padding layer 310 proximate to the internal portion.

Headband 300 may have any suitable shape, such as those described above with reference to headband 100 and headband 200.

In some embodiments, the materials and thickness of padding layer 310 can be selected such that padding layer 310 remains sufficiently flexible to allow the protective headband to maintain contact with a user's head along an entire circumference of the user's head. In an exemplary embodiment, padding layer 310 has a thickness of less than approximately 0.75 inches, 0.7 inches, 0.65 inches, 0.6 inches, 0.55 inches, 0.5 inches, 0.45 inches, 0.4 inches, 0.35 inches, 0.3 inches, 0.25 inches, 0.2 inches, 0.15 inches, 0.1 inches or 0.05 inches.

In some embodiments, padding layer 310 is formed from impact-resistant materials. For example, padding layer 310 may include at least one layer of elastomeric material. The elastomeric material may provide impact-resistance by absorbing and dissipating the force of impacts laterally along the surface of the elastomeric material. In one exemplary embodiment, padding layer 310 comprises a single layer of elastomeric material. In another exemplary embodiment, padding layer 310 comprises two or more layers of elastomeric material. Padding layer 310 may include the layers of elastomeric material directly adjacent each other, or may include a reinforcement or additional layer 328, such as a layer of high tensile strength fibrous material between the layers of elastomeric material.

Headband 300 may have at least one fabric layer or cover 330 in accordance with aspects of the present disclosure. Fabric cover 330 is configured to at least partially surround padding layer 310. Fabric cover 330 may desirably provide a more comfortable feeling for the user of headband 100 than direct contact with padding layer 310.

Referring now to FIG. 9, shown is an exemplary protective headband 300 including a fabric layer or cover 330 having at least one strip, patch or outer layer 340 in accordance with aspects of the present disclosure. In some embodiments, the at least one outer layer 340 comprises a soft flexible silicon strip, or any class of synthetic materials which are polymers strips, that can further deflect, distribute, and defuse impact energy and may help mitigate trauma to the head. For example, the at least one outer layer 340 may comprise any of a polymeric material such as rubber, silicone, or another elastomeric compound, composite material, soft material, hard material, elastic material, inelastic material, silicone, gel, foam, and plastic. In some embodiments, outer layer 340 may extend around the entire circumference of headband 300. In other embodiments, outer layer 340 may be segmented, as shown in FIG. 9, having a first outer layer 340a and a second outer layer 340b disposed on respective regions of the headband 300. The outer layer 340 may be substantially similar in width to padding layer 310 and/or fabric layer 330, or may be of reduced width to provide localized functionality, such as enhanced forehead control or targeted protection.

In some embodiments, outer layer 340 may include surface features or textures, such as friction features, a pattern of friction features, an array of bumps, raised portions, directional portions, indents, detents, bumps, ridges, knurling, or similar details, to improve grip, impact control, and energy dissipation. In some embodiments, the outer layer 340 may be formed of silicone or a silicone-based polymer strip or patch configured to replicate the tactile and mechanical response of human forehead skin. This configuration provides enhanced control and consistency when the user contacts an object, such as a soccer ball, with the forehead region. The silicone-based outer layer 340 may distribute and direct impact forces in a manner similar to the natural compliance of the user's skin, thereby allowing the user to maintain natural heading mechanics and directional steering without requiring adaptation or retraining. In some embodiments, the silicone-based material may further provide environmental resistance and improved durability during repeated impacts and cleaning cycles. The at least one outer layer 340 may be formed in any size, for example having a horizontal width ranging between 0.25 inches and 20 inches, and a vertical width ranging between 0.125 inches and 5 inches. The at least one outer layer 340 may have any thickness, for example a thickness ranging between 0.03125 inches and 1 inch. The at least one outer layer 340 may have any number of layers (e.g., sub-layers) and materials, such as an outer harder layer and inner softer layer, or vice versa. The at least one outer layer 340 may be formed in any shape, such as for example rectangular, square, circular, round, ovular, oblong, irregular, hour-glass, trapezoidal, or may be formed in one more shapes thereof at least partially joined, or adjacent to one another.

In some embodiments, headband 300 may include multiple layers of protective material configured to mitigate the risk of traumatic brain injury, including but not limited to concussion, contusion, or other cranial trauma. In an exemplary embodiment, headband 300 includes at least one padding layer 310 (e.g., foam layer) and at least one additional layer 328 (e.g., a high-tensile strength fibrous layer), such as an aramid or Kevlar® layer. The at least one padding layer 310 may comprise a single foam layer, multiple foam layers, and/or multiple foam layers of differing durometer values to provide progressive energy absorption. The additional layer 328 (e.g., aramid or Kevlar® layer) may be positioned on at least one side or surface of padding layer 310, such as inwardly and/or outwardly of padding layer 310, or between adjacent padding layer 310, to enhance tensile strength and resistance to penetration. In some embodiments, the combination of the outer layer 340, the at least one padding layer 310, and the at least one additional layer 328 provide a shielding effect, dissipating impact forces laterally and circumferentially around the headband to minimize force transmission into the user's skull.

Referring now to FIGS. 10-13, portions of headband 300, such as at least one padding layer 310 and/or additional layer 328, may include at least one break or gap 370 and/or one or more expansion joint 372 disposed along at least a portion of the respective length or circumference. The break or gap 370 and/or expansion joint 372 are configured to allow controlled expansion and contraction of the headband 300 to accommodate different head sizes, improve fit, and enhance comfort during use. In some embodiments, the break or gap 370 and/or expansion joint 372 may be formed as gaps, slits, perforations, or as tabbed and slotted regions for padding layer 310 and/or additional layer 328. FIG. 10 illustrates the break or gap 370 in an expanded state, showing increased spacing between adjacent portions of the headband 300. FIG. 11 illustrates the break or gap 370 in a non-expanded (resting) state, wherein the padding layer 310 and additional layer 328 are flush and continuous. FIG. 12 again illustrates the break or gap 370 in an expanded state, demonstrating the flexibility and elastic recovery of the material during donning or use. It should be appreciated that headband 300 may comprise any number of break or gap 370 and/or expansion joint 372. The configuration of break or gap 370 and/or expansion joint 372 allows the headband 300 to achieve one-size-fits-all capability without the need for separate mechanical adjustment mechanisms, while maintaining consistent protective coverage around the user's head.

Referring now to FIG. 13, in some embodiments, headband 300 comprises an tabbed and slotted, interlocking and/or dovetailing expansion joint 372 configured to maintain protective coverage during expansion. In such embodiments, portions of headband 300, such as padding layer 310 and/or additional layer 328, may include interlocking, dovetailing, tabbed, slotted, or shaped features or regions that allow one portion of material to slide relative to, be positioned next to, and/or at least partially overlap the other, while material around the circumference of the headband remains substantially continuous. For example, FIG. 13 shows a first portion 374 and a second portion 376 that may be configured such that, during expansion, the first portion 374 slides relative to the second portion 376 to allow circumferential elongation of the headband 300 without creating substantial gaps in coverage. This tabbed and slotted or dovetailing configuration ensures that the padding and reinforcing layers continue to cover a substantial portion of the user's head even during expansion or stretching, preserving the impact protection characteristics of the headband. The expansion joint 372 may comprise any number of tabs and slots, such as one tab and two adjacent slots, or vice versa, or configured in a saw-tooth configuration. The portions of the expansion joint 372 may be formed in any shapes, such as rectangular shapes as show, but also any of square, rounded, semi-circular, triangular, trapezoidal, irregular, oblong, and any combinations thereof.

In some embodiments, the headband 300 comprises two or more pieces or lengths of padding layer 310 and/or additional layer 328 that form the headband, wherein a break or gap 370 and/or an expansion joints 372 are positioned between each piece or length. In some embodiments, the elastic connectors (301, 302) at least partially cover at least one of the break or gap 370, or expansion joint 372, and connect the lengths of padding layer 310, and/or the additional layer 328.

In some embodiments, portions of the headband 300 (e.g., padding layer 310, additional layer 328, fabric layer 330) may exhibit varying elasticity along its length or around its circumference. For example, a front region of the headband may exhibit reduced elasticity to improve stability and positioning during high-impact activities, while lateral and rear portions may exhibit increased elasticity to improve comfort and accommodate a broader range of head sizes. In alternative embodiments, headband 300 may exhibit uniform elasticity around its circumference to provide a universal fit. Additionally, headband 300 may include an optional adjustable attachment mechanism, such as a hook-and-loop fastener, buckle, or clasp, allowing selective tightening or loosening as desired.

Suitable materials for forming the elastomeric layer(s) (110, 210, 310) include, but are not limited to, impact resistant material, elastomeric material, urethane rubbers, silicone rubbers, nitrile rubbers, butyl rubbers, acrylic rubbers, natural rubbers, styrene-butadiene rubbers, plastic, foam, open-cell foam, multi-durometer foam, memory foam, gel, hydrogel, and the like. In general, any suitable elastomer material can be used to form the above-described elastomeric layers without departing from the scope of the present disclosure.

Suitable materials for forming the additional layer, such as a layer of high tensile strength fibrous material include, but are not limited to, soft material, woven material, biocompatible material, fibrous material, high tensile strength fibrous material, natural material, synthetic material, cotton fiber, elastic fiber, elastic material, inelastic material, aramid fibers, fiberglass, Kevlar®, cotton fiber, other high tensile strength fibers, and the like. The fibers may be woven to form a cloth layer that is disposed between and generally separates the opposing elastomeric layers. The additional layer (e.g., high tensile strength fibrous material layer) may desirably block and redirect impact energy that passes through one of the elastomeric layers. Additional description of materials for forming padding layer 110 and additional layer (e.g., high tensile strength fibrous material layer) may be found in U.S. Pat. No. 10,716,353, U.S. patent application Ser. No. 13/975,447, U.S. patent application Ser. No. 18/213,603, U.S. patent application Ser. No. 18/407,568, U.S. patent application Ser. No. 09/978,130, the contents of each of which are incorporated herein by reference in their entirety for all purposes.

Headbands 100, 200, 300 as described herein may be utilized in a wide range of applications and by users of different age groups and physical needs. In some embodiments, the headband may be used for athletic activities to reduce the risk of traumatic brain injury. In other embodiments, the headbands may be worn following cranial or neurosurgical procedures to provide cushioning and protection during recovery. In further embodiments, the headbands may be configured for use by toddlers, children, or individuals with special needs to protect against incidental head impacts or falls. In all embodiments, the headband provides an optimal combination of protection, comfort, and fit, offering multi-layered impact attenuation, lateral dissipation of force, skin-friendly materials that minimize irritation, and structural adaptability for universal use. The disclosed headbands may be worn with or underneath hats, scarves, helmets, sweatbands and other wearables. Further, headbands 100, 200, and 300 may be integrated into wearables, such as a hat, a baseball cap, a winter hat (e.g., a beanie), and may provide protection during related activities (e.g., sports, skiing, snowboarding). Thus, a head-mounted wearable garment comprising at least one disclosed headband integrated within (e.g., sewn or fused in) is also claimed.

Although the disclosed devices are illustrated and described herein with reference to specific embodiments, the disclosure is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the true spirit and scope of the disclosure. In particular, any of the features described herein with respect to one embodiment may be provided in any of the other embodiments.

In the foregoing Detailed Description, it can be seen that various features are grouped together in a single embodiment for the purpose of clarity and brevity of the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the embodiments require more features than are expressly recited herein. Rather, the disclosure is to encompass all variations and modifications to the disclosed embodiments that would be understood to the skilled artisan in light of the disclosure.

EXPERIMENTAL EXAMPLES

The disclosed devices are further described in detail by reference to the following experimental examples. These examples are provided for purposes of illustration only, and are not intended to be limiting unless otherwise specified. Thus, the disclosed devices should in no way be construed as being limited to the following examples, but rather, should be construed to encompass any and all variations which become evident as a result of the teaching provided herein.

Without further description, it is believed that one of ordinary skill in the art can, using the preceding description and the following illustrative examples, make and utilize the devices of the present disclosure. The following working examples therefore, specifically point out the exemplary embodiments of the present disclosure, and are not to be construed as limiting in any way the remainder of the disclosure.

An embodiment of a disclosed headband was tested for performance in a head-to-head collision. Referring now to FIG. 14, shown is an exemplary impact testing rig configured to simulate head-to-head collision forces and evaluate the protective performance of a headband constructed in accordance with embodiments of the present disclosure. The testing rig includes a first test dummy head and a second test dummy head, each mounted on opposing linear actuators configured to move the heads toward each other at controlled velocities. The first test dummy head is fitted with a protective headband as described herein. The second test dummy head is left uncovered to provide a baseline comparison of impact response. Each test dummy head comprises one or more sensors for measuring acceleration, rotation, and/or impact force.

As shown in FIG. 15, the two test dummy heads are positioned immediately prior to collision, with the right test dummy head approaching the left test dummy head—the left test dummy wearing the headband.

Referring now to FIG. 16, the moment of impact is illustrated, wherein the headband directly receives the majority of the collision force. During the event, the headband deforms elastically, dissipating energy laterally across the headband surface, while the padding layer compresses to absorb residual impact force. The combination of these layers enables multi-directional energy dispersion and prevents concentration of stress at localized regions on the skull surface.

Testing demonstrated that the protective headband of the present disclosure significantly reduced impact severity when compared to a non-protected headform. Specifically, quantitative analysis of accelerometer data embedded in the test dummy heads indicated that the peak linear acceleration was reduced by more than 50%, and rotational acceleration, correlated with concussion risk, was reduced by more than 70%. These results illustrate that the structural and material features described above provide substantial protective benefit against impact-induced head injury.

Accordingly, the headband described herein exhibits improved impact attenuation, energy distribution, and recovery characteristics compared to conventional padded headgear, offering a practical solution for reducing injury risk in contact sports and other activities where head collisions are common.

The following publications are each hereby incorporated herein by reference in their entirety:

• • U.S. Pat. No. 10,716,353, entitled “Protective Headband”
  • U.S. patent application Ser. No. 13/975,447, entitled “Impact Dissipating Fabric”
  • U.S. patent application Ser. No. 18/213,603, entitled “Apparatuses, systems and methods for equipment for protecting the human body by absorbing and dissipating forces imparted to the body”
  • U.S. patent application Ser. No. 18/407,568, entitled “Apparatuses, systems and methods for equipment for protecting the human body by absorbing and dissipating forces imparted to the body”
  • U.S. patent application Ser. No. 09/978,130, entitled “Athletic clothing with sting reduction padding”

The disclosures of each and every patent, patent application, and publication cited herein are hereby incorporated herein by reference in their entirety. While this device has been disclosed with reference to specific embodiments, it is apparent that other embodiments and variations of this device may be devised by others skilled in the art without departing from the true spirit and scope of the invention.