CN118177445A - Protective cap - Google Patents

Abstract

A protective cap comprising a shell and an impact absorbing liner, the shell and the impact absorbing liner being constructed of a material designed to provide impact protection to a wearer. In some embodiments, the outer shell includes an outer surface pattern and/or an inner surface pattern for providing better grip and reduced rotation between the outer shell and the impact absorbing liner and/or the outer shell and a hat worn by a user to cover the protective cap.

Description

Protective cap

Cross-reference to related patent applications

The application claims the benefit and priority of U.S. provisional application No. 63/387,421, filed on 12/14 of 2022, which is incorporated herein by reference in its entirety.

Background

The present invention relates generally to the field of protective equipment. The present invention relates in particular to various protective or crash cap designs constructed of materials that provide additional protection to the head of a user from impact and/or collision. The helmet is smaller and has a lower profile than a protective helmet or helmet.

Disclosure of Invention

One embodiment of the present invention relates to a protective cap. The protective cap includes a housing. The housing includes an exterior surface, an interior surface defining a cavity sized to receive a head of a user, and a crown portion. The exterior surface includes a patterned portion. The patterned portion is configured to engage an inner surface of a headgear covering the headgear. The crown portion is configured to cover a portion of the head of the user. The housing further includes a bottom section. The bottom section defines a lower circumference of the housing. The protective cap further includes an impact absorbing liner positioned within the outer shell and engaged with an interior surface of the outer shell. The exterior surface of the outer shell includes a pattern that engages the interior surface of a cap that covers the protective cap.

Another embodiment of the invention is directed to a crash cap. The crash cap includes a housing. The shell includes an exterior surface, an interior surface, a crown portion, and a sole section. The exterior surface includes a patterned portion. The interior surface defines a cavity sized to receive a head of a user. The crown portion is configured to cover a portion of the head of the user. The bottom section defines a lower circumference of the housing. The housing further includes a front portion, a rear portion, a pair of side portions, and an adjustable section. The rear portion is opposite the front portion. The pair of side portions extend downwardly from the crown portion and are positioned between the anterior portion and the posterior portion. An adjustable section extends along a bottom section of each of the pair of side portions. The adjustable section includes a shoulder extending along a longitudinal axis of the crash cap. The crash cap further includes an impact absorbing liner positioned within the shell and coupled to an interior surface of the shell.

Another embodiment of the invention is directed to a crash cap. The crash cap includes a housing. The housing includes an exterior surface, an interior surface, a crown portion, and a sole section, the interior surface defining a cavity sized to receive a head of a user. The crown portion is configured to cover a portion of the head of the user. The bottom section defines a lower circumference of the housing. The housing further includes a plurality of protruding structures extending away from the exterior surface, and a plurality of recessed sections. Each recessed section is positioned within and recessed relative to the protruding structure. The crash cap further includes an impact absorbing liner positioned within the shell and engaged with an interior surface of the shell.

In a specific embodiment, the interior surface of the shell includes a pattern that engages the exterior surface of the impact absorbing liner. The engagement between the outer shell and the impact absorbing liner is configured to reduce rotation between the outer shell and the impact absorbing liner. In a particular embodiment, the housing includes a shoulder positioned between the thick portion of the housing and the adjustable portion of the housing.

Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.

The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain the principles and operations of various embodiments.

Drawings

The present application will become more fully understood from the detailed description given below in conjunction with the accompanying drawings, wherein like reference numerals designate like elements, and in which:

FIG. 1 is a side view of a crash cap positioned on a wearer's head with an impact absorbing liner removed according to an exemplary embodiment.

Fig. 2 is a perspective view from above of the shell of the crash cap of fig. 1, according to an exemplary embodiment.

Fig. 3 is a side view of the shell of the crash cap of fig. 1 in accordance with an exemplary embodiment.

Fig. 4 is a bottom view of an impact absorbing liner according to an exemplary embodiment.

Fig. 5 is a view from below of a crash cap having the impact absorbing liner of fig. 4, according to an exemplary embodiment.

Fig. 6 is a perspective view of the crash cap of fig. 5 in accordance with an exemplary embodiment.

Fig. 7 is a bottom view of an impact absorbing liner according to another exemplary embodiment.

Fig. 8 is a view from below of a crash cap having the impact absorbing liner of fig. 7, according to an exemplary embodiment.

Fig. 9 is a perspective view of the crash cap of fig. 8 in accordance with an exemplary embodiment.

Fig. 10 is a view from below of a protective cap with an impact absorbing liner according to another exemplary embodiment.

Fig. 11 is a perspective view of a housing according to another exemplary embodiment.

Fig. 12 is a perspective view from below of the housing of fig. 11, according to an exemplary embodiment.

Fig. 13 is a perspective view of a protective enclosure according to another exemplary embodiment.

Fig. 14 is a perspective view from below of the housing of fig. 13, according to an exemplary embodiment.

Fig. 15 is a perspective view of a shell of a crash cap according to another exemplary embodiment.

Detailed Description

Referring generally to the drawings, various embodiments of a protective cap, shown as a crash cap, are shown. As will be generally understood, many conventional helmets are designed to provide impact protection against falling objects, while crash caps provide protection when the wearer is concerned with a lower level of impact (such as impacting the wearer's head). The crash cap has a lower profile and is less bulky than the crash cap, allowing the crash cap to be worn under the cap or other headgear (if desired). The various embodiments of the crash caps discussed herein include various designs and materials that provide improved ability to absorb impact (i.e., head impact against an object, ceiling, duct, underside of a vehicle, etc.). In particular, various crash cap designs include an outer shell and an impact absorbing liner positioned within the outer shell.

Applicants believe that the crash caps discussed herein are designed to provide impact absorption to the wearer while having a lower profile (i.e., thinner, less bulky) than conventional crash caps or other head protectors (i.e., helmets). In some embodiments, applicants have devised a crash cap that utilizes the materials and structures discussed herein to provide improved structural performance, thereby allowing the design of a crash cap having a low profile. This design improvement allows for a crash cap that provides a high level of protection while allowing for better user comfort and flexibility in using the crash cap with various coverings (i.e., caps, etc.), which is particularly important where the user may wear the device for many hours during a weekday/shift.

Additionally, in various embodiments of the crash cap discussed herein, the outer shell includes an outer surface pattern. Applicants believe that the outer surface pattern provides a grip between the crash cap and a cap that a user may wear on the crash cap, thereby reducing rotation and/or relative movement between the crash cap and the cap and improving impact performance. The vent holes and/or channels are positioned within the recessed portion of the shell to provide a passageway for airflow within the crash cap. In some embodiments, the shell of the crash cap includes a surface pattern on an inner surface (i.e., the surface that engages the impact absorbing liner) that is used to grip and/or secure the impact absorbing liner to the shell and reduce rotation between the shell and the impact absorbing liner. In particular embodiments, the impact absorbing liner includes structure (i.e., plugs, clips, etc.) that mechanically secures the impact absorbing liner to the shell. In particular embodiments, the impact absorbing liner is coupled to the outer shell using hook and loop fasteners or structures.

Further, in various embodiments, the outer shell of the crash cap includes thinned portions, allowing the crash cap to be easily adjusted and customized to fit within a selected cap. In particular, the adjustable portion includes a step or shoulder that transitions between the thicker portion of the crash cap and the adjustable portion. Similarly, some embodiments include vertical (i.e., extending toward the crown) slots in the front portion of the housing that allow the housing to accommodate a variety of head sizes and hairstyles.

Referring to fig. 1, a perspective view of a protective hat or cap (shown as crash cap 10) according to an exemplary embodiment is shown. The crash cap 10 includes a protective shell 12 and an impact absorbing liner 60 (see, e.g., fig. 4). In particular embodiments, the housing 12 is formed from a rigid material (e.g., a rigid polymeric material). The housing 12 includes an exterior surface 18 and an interior surface 20 (see, e.g., fig. 2-3). The interior surface 20 defines a cavity 22 (see, e.g., fig. 2) sized to receive the head of the user and/or wearer 16. The exterior surface 18 of the housing 12 faces and/or engages the interior surface of the cap or cap 14.

Referring to fig. 2-3, details of the guard housing 12 are shown according to an exemplary embodiment. The housing 12 includes a crown or crown portion 24 and a bottom section 26 defining a lower circumference of the housing 12. The housing 12 further includes a front portion 28 and a rear portion 30 opposite the front portion 28. A pair of opposing side portions 32 of the shell 12 extend downwardly (i.e., toward the wearer 16) from the crown 24 between the front portion 28 and the rear portion 30.

The housing 12 further includes a plurality of apertures or vents 34. A vent 34 extends through the housing 12 to provide fluid communication between the cavity 22 and ambient air adjacent the exterior surface 18 of the housing 12. In a particular embodiment, the vent holes 34 are located along opposite side portions 32 of the housing 12. In other embodiments, the vent 34 is positioned on other portions of the housing 12 (i.e., crown, front, rear, etc.). The shell 12 further includes a recessed section 36 positioned between the front portion 28 and the rear portion 30 of the crash cap 10 proximate the ear of the wearer 16. In particular embodiments, the recessed section 36 extends a height above a portion of the bottom section 26 proximate the front portion 28 and/or the rear portion 30 of the bumper cap 10.

The exterior surface 18 of the housing 12, and in particular the crown 24, includes a patterned or textured portion 38. As discussed above, applicants believe that the patterned portion 38 on the shell 12 provides a grip between the crash cap 10 and the cap 14 that the user 16 may wear on the crash cap 10, thereby reducing rotation between the exterior surface 18 of the shell 12 and the interior surface of the cap 14. In other words, when the patterned portion 38 engages the cap 14, the patterned portion 38 resists rotation of the cap such that rotation between the crash cap 10 and the cap 14 is reduced.

In particular embodiments, patterned portion 38 extends along crown 24 between front portion 28 and rear portion 30 of housing 12. Patterned portion 38 includes raised structures or protruding structures 40 while the other sections are recessed central regions 42. In such an embodiment, the protruding structures 40 each have an outer surface 41, and the outer surfaces 41 of the protruding structures 40 together define the outermost surface of the crown 24 of the crash cap 10. In a particular embodiment, patterned portion 38 includes a hexagonal pattern. In other embodiments, patterned portion 38 is a different shape (i.e., triangular, square, etc.).

The housing 12 further includes one or more recesses 44. The recessed portion 44 is positioned between the crown 24 and the opposite side portions 32 of the housing 12. In such an embodiment, the recessed portion 44 is recessed below both the protruding structures 40 and the recessed central region 42 of the patterned portion 38.

A vent passageway 46 is positioned within the recess 44. The vent passage 46 extends through the housing 12 to provide fluid communication between the cavity 22 and ambient air adjacent the exterior surface 18 of the housing 12. The applicant believes that by locating the vent passage 46 within the recess 44 (and below/closer to the wearer's head than the outer surface 41 of the projection arrangement 40), airflow is improved. The vent passage 46 extends between the front portion 28 and the rear portion 30 of the shell 12 in a direction generally along a major or longitudinal axis 48 of the crash cap 10. In various embodiments, the vent channel 46 extends in a non-linear manner (i.e., is stepped or patterned). In a particular embodiment, the vent channel 46 extends in the shape of the patterned portion 38 (i.e., half of a trapezoid or hexagon).

Referring to fig. 3, each opposing side portion 32 includes an adjustable section 50 along the bottom section 26. The adjustable section 50 includes a step or shoulder 52 that transitions between a first thick portion 54 of the crash cap 10 and/or the shell 12 and a second thin portion 56 that is easily adjustable. In other words, the shoulder 52 is a stepped transition between the thick portion 54 and the thin portion 56 of the housing 12. In particular embodiments, shoulder 52 extends along longitudinal axis 48. As previously discussed, the thin portion 56 of the shell 12 allows the crash cap 10 to be easily adjusted and customized to fit within a particular cap 14. The thick portion 54 has a first thickness T1 and the thin portion has a second thickness T2. In a specific embodiment, T1 is different from T2. In a specific embodiment, T1 is greater than T2.

Referring to fig. 2, the front portion 28 of the housing 12 further includes one or more vertical slots 58. Vertical slots 58 extend from the bottom section 26 toward the crown 24 of the housing 12. In particular embodiments, the vertical slots 58 extend in a direction substantially perpendicular (e.g., 90 degrees plus or minus 10 degrees) to the longitudinal axis 48. In various embodiments, the rear portion 30 of the housing 12 further includes one or more vertical slots 58. The vertical slots 58 allow the housing 12 to accommodate a variety of head sizes and/or hairstyles of users 16 by providing additional flexibility and/or space at the front portion 28 and/or the rear portion 30.

Referring to fig. 4, a bottom view of an impact absorbing liner 60 according to an exemplary embodiment is shown. The impact absorbing liner 60 may be used with an outer shell, such as the outer shell 12, to form a crash cap, such as the crash cap 10. When the crash cap 10 is assembled, the impact absorbing liner 60 is positioned and/or coupled within the cavity 22 of the shell 12. The impact absorbing liner 60 includes an outer surface 62 facing the inner surface 20 of the shell 12 and an inner surface 64 facing inwardly (i.e., toward the cap wearer 16). Applicant believes that the impact absorbing liner 60 provides improved engagement and/or grip between the impact absorbing liner 60 and the head of the cap wearer 16, thereby reducing rotation between the cap 10 and the wearer 16 to improve impact performance. In particular embodiments, impact absorbing liner 60 is formed from a polymer foam material. In a particular embodiment, impact absorbing liner 60 is formed from Expanded Polystyrene (EPS). In another embodiment, the impact absorbing liner 60 is formed of a moisture absorbing and sweat releasing material (moistures WICKING MATERIAL).

The impact absorbing liner 60 includes a plurality of openings or vents 66. The vent holes 66 extend through the impact absorbing liner 60 to provide fluid communication between the cavity 22 and ambient air proximate the exterior surface 18 of the shell 12, even when the crash cap 10 is assembled (see, e.g., fig. 5). In a particular embodiment, the impact absorbing liner 60 includes a plurality of apertures 68 that function as ventilation holes. The aperture 68 extends through the impact absorbing liner 60 to provide fluid communication between the cavity 22 and ambient air proximate the exterior surface 18 of the shell 12, even when the crash cap 10 is assembled (see, e.g., fig. 5). In a particular embodiment, the vent 66 has a first size and the aperture 68 has a second size that is smaller than the first size.

Referring to fig. 5-6, according to an exemplary embodiment, the crash cap 10 is shown fully assembled (i.e., including both the outer shell 12 and the impact absorbing liner 60). In particular embodiments, the vent 66 is positioned along the interior surface 20 of at least one of the opposing side portions 32, front portion 28, and/or rear portion 30 of the housing 12. In particular embodiments, aperture 68 is positioned at crown 24 (i.e., between opposing side portions 32) along interior surface 20.

Referring to fig. 7-9, views of an impact absorbing liner 70 and a crash cap 110 according to another exemplary embodiment are shown. The crash cap 110 includes the outer shell 12 and may be used with the impact absorbing liner 70. The crash cap 110 is substantially identical to the crash cap 10, except for the differences discussed herein. The crash cap 110 includes the protective shell 12 and the impact absorbing liner 70 (see, e.g., fig. 8-9).

Referring to fig. 7, a bottom view of an impact absorbing liner 70 according to an exemplary embodiment is shown. The impact absorbing liner 70 may be used with an outer shell, such as the outer shell 12, to form a crash cap, such as the crash cap 110. When the crash cap 110 is assembled, the impact absorbing liner 70 is positioned and/or coupled within the cavity 22 of the shell 12. The impact absorbing liner 70 includes an outer surface 72 that faces the inner surface 20 of the shell 12 and an inner surface 74 that faces inwardly (i.e., toward the cap wearer 16). Applicant believes that the impact absorbing liner 70 provides engagement and/or grip between the impact absorbing liner 70 and the head of the cap wearer 16, thereby reducing rotation between the cap 110 and the wearer 16 to improve impact performance.

In various embodiments, the impact absorbing liner 70 is formed of a strain rate sensitive material, meaning that the properties of the impact absorbing liner 70 change as the strain rate increases. In particular, in such embodiments, the impact absorbing liner 70 is a material in which the stiffness of the impact absorbing liner 70 increases under impact. In some embodiments, the impact absorbing liner 70 is an intumescent material (a shear thickening material). In various embodiments, the impact absorbing liner 70 comprises a plurality of units. In a particular embodiment, the cells of the impact absorbing liner 70 have an anisotropic geometry such that the material has different responses and behaviors to mechanical deformation in all three directions (X, Y, Z). In another embodiment, the impact absorbing liner 70 is formed of a moisture absorbing and sweat releasing material.

The impact absorbing liner 70 includes a plurality of openings or vents 76. The vent 76 extends through the impact absorbing liner 70 to provide fluid communication between the cavity 22 and ambient air proximate the exterior surface 18 of the shell 12, even when the crash cap 110 is assembled (see, e.g., fig. 8). In a particular embodiment, the impact absorbing liner 70 includes a plurality of apertures 78 that function as ventilation holes. The aperture 78 extends through the impact absorbing liner 70 to provide fluid communication between the cavity 22 and ambient air proximate the exterior surface 18 of the shell 12, even with the crash cap 110 assembled (see, e.g., fig. 8). In a particular embodiment, the vent 76 has a first size and the aperture 78 has a second size that is smaller than the first size.

Referring to fig. 8-9, according to an exemplary embodiment, the crash cap 110 is shown fully assembled (i.e., including both the shell 12 and the impact absorbing liner 70). In particular embodiments, the vent 76 is positioned along the interior surface 20 of at least one of the opposing side portions 32, the front portion 28, and/or the rear portion 30 of the housing 12. In particular embodiments, the aperture 78 is positioned at the crown 24 (i.e., between the opposing side portions 32) along the interior surface 20.

Referring to fig. 10, a perspective view from below of the crash cap 210 is shown according to another exemplary embodiment. The crash cap 210 may be used with the impact absorbing liner 60 or 70 and/or a shell such as the shell 12. The crash cap 210 is substantially identical to the crash caps 10 and 110, except for the differences discussed herein, and the components of the crash cap 210 are correspondingly given the same reference numerals, plus 100 or 200.

The crash cap 210 includes a protective shell 212 and an impact absorbing liner 270. In particular embodiments, housing 212 is formed from a rigid material, such as a rigid polymeric material. The housing 212 includes an exterior surface 218 and an interior surface 220. The interior surface 220 defines a cavity 222 sized to receive a user and/or wearer's head. The housing 212 further includes a front portion 228 and a rear portion 230 opposite the front portion 228. A pair of opposing side portions 232 of the housing 212 extend downwardly (i.e., toward the wearer) from the crown between the front portion 228 and the rear portion 230 of the housing 212. The housing 212 further includes a plurality of apertures or vents 234. The vent 234 extends through the housing 212 to provide fluid communication between the cavity 222 and ambient air proximate the exterior surface 218 of the housing 212.

When the crash cap 210 is assembled, the impact absorbing liner 270 is positioned and/or coupled within the cavity 222 of the shell 212. The impact absorbing liner 270 includes an outer surface (see, e.g., 72 in fig. 9) that faces the inner surface 220 of the outer shell 212 and an inner surface 274 that faces inwardly (i.e., toward the cap wearer). The applicant believes that the impact absorbing liner 270 provides engagement and/or grip between the impact absorbing liner 270 and the head of the cap wearer, thereby reducing rotation between the cap 210 and the wearer to improve impact performance.

The impact absorbing liner 270 includes a plurality of structures, shown as plugs 280. The plug 280 extends toward the interior surface 220 of the shell 212 and engages the interior surface 220 and/or the shell 212 to securely retain and/or lock the impact absorbing liner 270 to the shell 212. The applicant believes that this engagement between the plug 280 of the impact absorbing liner 270 and the outer shell 212 reduces rotation between the cap 210 and the impact absorbing liner to further improve impact performance. In various embodiments, the impact absorbing liner 270 includes other structures (i.e., clips, snaps, etc.) that securely couple the impact absorbing liner 270 to the shell 212.

Referring to fig. 11-12, views of an outer shell 312 for a crash cap according to another exemplary embodiment are shown. The outer shell 312 may be used with the impact absorbing liners 60, 70, and/or 270. Except for the differences discussed herein, the housing 312 is substantially identical to the housing 12, 212. The housing 312 includes an exterior surface 318 and an interior surface 320. The interior surface 320 defines a cavity 322 (see, e.g., fig. 12) sized to receive a user and/or wearer's head. The exterior surface 318 of the housing 312 faces and/or engages the interior surface of a hat or cap (see, e.g., 14 in fig. 1).

The housing 312 includes a crown 324 and a bottom section 326 that defines a lower circumference of the housing 312. The housing 312 further includes a front portion 328 and a rear portion 330 opposite the front portion 328. A pair of opposing side portions 332 of the shell 312 extend downwardly from the crown 324 (i.e., toward the wearer of the crash cap) and between the front portion 328 and the rear portion 330. In a particular embodiment, the housing 312 includes a plurality of apertures or vents 334. The vent 334 extends through the housing 312 to provide fluid communication between the cavity 322 and ambient air proximate the exterior surface 318 of the housing 312. In a particular embodiment, the vent holes 334 are positioned along opposite side portions 332 of the housing 312. In other embodiments, the vent 334 is positioned on other portions of the housing 12 (i.e., crown, front, rear, etc.).

The outer surface 318 of the housing 312 (and in particular the crown 324) includes a patterned or textured portion 338. As discussed above, applicants believe that the patterned portion 338 on the outer shell 312 provides a grip between the crash cap and a cap that the user may wear on the crash cap (see, e.g., 14 in fig. 1), thereby reducing rotation between the outer surface 318 of the outer shell 312 and the inner surface of the cap.

In a particular embodiment, the patterned portion 338 extends along the crown 324 between the front portion 328 and the rear portion 330 of the housing 312. A section of patterned portion 338 includes a raised structure or protruding structure 340 extending away from outer surface 318, and other sections 342 are recessed relative to protruding structure 340 (i.e., recessed relative to an outer surface of structure 340). In a particular embodiment, the patterned portion 338, and in particular the protruding structure 340, includes a cross-hatched shaped pattern. In other embodiments, patterned portion 338 includes patterns having different shapes (i.e., triangular, square, hexagonal, etc.). In a particular embodiment, the recess or recessed section 342 of the patterned portion 338 has a quadrilateral shape (i.e., diamond, parallelogram, rectangle, square, etc.). In other embodiments, the depressions or recessed sections 342 of the patterned portion 338 are differently shaped (i.e., triangular, square, hexagonal, polygonal, etc.).

Referring to fig. 12, a perspective view from below of the housing 312 is shown according to an exemplary embodiment. The shell 312 includes a surface pattern on the interior surface 320 (i.e., the surface that engages the impact absorbing liner) that grips and/or secures the impact absorbing liner to the shell 312 and reduces rotation between the shell 312 and the impact absorbing liner. The protruding structures 340 form corresponding recessed structures 344 along the interior surface 320. Similarly, the recessed section 342 on the exterior surface 318 creates a corresponding protrusion 346 that extends inwardly away from the interior surface 320 (i.e., toward the impact absorbing liner and/or the user of the crash cap).

Referring to fig. 13-14, views of an outer shell 412 for a crash cap according to another exemplary embodiment are shown. The outer shell 412 may be used with impact absorbing liners 60, 70 and/or 270. Except for the differences discussed herein, the housing 412 is substantially identical to the housing 12, 212, 312. The housing 412 includes an exterior surface 418 and an interior surface 420. The interior surface 420 defines a cavity 422 (see, e.g., fig. 14) sized to receive a user and/or wearer's head. An exterior surface 418 of the housing 412 faces and/or engages an interior surface of a hat or cap (see, e.g., 14 in fig. 1).

The housing 412 includes a crown 424 and a bottom section 426 defining a lower circumference of the housing 412. The housing 412 further includes a front portion 428 and a rear portion 430 opposite the front portion 428. A pair of opposing side portions 432 of the shell 312 extend downwardly from the crown 424 (i.e., toward the wearer of the crash cap) and are positioned between the front portion 428 and the rear portion 430. In a particular embodiment, the housing 412 includes a plurality of apertures or vents 434. The vent 434 extends through the housing 412 to provide fluid communication between the cavity 422 and ambient air proximate the exterior surface 418 of the housing 412. In a particular embodiment, the vent 434 is positioned along opposite side portions 432 of the housing 312. In other embodiments, the vent 434 is positioned on other portions of the housing 412 (i.e., crown, front, rear, etc.).

The interior surface 420 of the housing 412, and in particular the crown 424, includes a patterned or textured portion 438. As discussed above, applicants believe that the patterned portion 438 on the shell 412 provides gripping and/or fastening of the impact absorbing liner to the shell 412 and reduces rotation between the shell 412 and the impact absorbing liner.

In a particular embodiment, the patterned portion 438 extends along the crown 424 between the front portion 428 and the rear portion 430 of the interior surface 420 of the housing 412. The sections of the patterned portion 438 include raised structures or protruding structures 440 that extend away from the interior surface 420 (i.e., toward the wearer of the crash cap), and the other sections 442 are recessed or recessed relative to the protruding structures 440. In a particular embodiment, the patterned portion 438, and in particular the protruding structures 440, include a hexagonal or honeycomb-like pattern. In other embodiments, patterned portion 438 comprises a different shape (i.e., triangle, square, polygon, etc.).

Referring to fig. 15, a perspective view of an outer shell 512 for a crash cap according to another exemplary embodiment is shown. The shell 512 may be used with impact absorbing liners 60, 70 and/or 270. Except for the differences discussed herein, housing 512 is substantially identical to housings 12, 212, 312 and 412. The housing 512 includes an exterior surface 518 and an interior surface 520. The interior surface 520 defines a cavity 522 (see, e.g., fig. 12) sized to receive a user and/or wearer's head. The exterior surface 518 of the housing 512 faces and/or engages the interior surface of a hat or cap (see, e.g., 14 in fig. 1).

The housing 512 includes a crown 524 and a bottom section 526 that defines a lower circumference of the housing 512. The housing 512 further includes a front portion 528 and a rear portion 530 opposite the front portion 528. A pair of opposing side portions 532 of the shell 512 extend downwardly from the crown 524 (i.e., toward the wearer of the crash cap) and between the front portion 528 and the rear portion 530. In a particular embodiment, the housing 512 includes a plurality of apertures or vents 534. The vent 534 extends through the housing 512 providing fluid communication between the cavity 522 and ambient air proximate the exterior surface 518 of the housing 512. In a particular embodiment, the vent 534 is located along opposite side portions 532 of the housing 512. In other embodiments, the vent 534 is positioned on other portions (i.e., crown, front, rear, etc.) of the housing 512.

The exterior surface 518 of the housing 512 (and in particular the crown 524) includes a patterned or textured portion 538. As discussed above, applicants believe that the patterned portion 538 on the outer shell 512 provides a grip between the crash cap and a cap that a user may wear on the crash cap (see, e.g., 14 in fig. 1), thereby reducing rotation between the exterior surface 518 of the outer shell 512 and the interior surface of the cap.

In a particular embodiment, the patterned portion 538 extends between the front portion 528 and the rear portion 530 of the housing 512 along the crown 524. The sections of patterned portion 538 include raised structures or protruding structures 540 that extend away from outer surface 518, and other sections 542 are recessed relative to protruding structures 540 (i.e., recessed relative to the outer surface of structures 540). The protruding structures 540 each have an outer surface 541, and the outer surfaces 541 of the protruding structures 540 together define the outermost surface of the crown 524. In various embodiments, recessed section 542 is positioned within protruding structure 540 and recessed relative to protruding structure 540.

In various embodiments, patterned portion 538, and in particular protruding structure 540, comprises a hexagonal pattern. In various other embodiments, patterned portion 538 includes patterns having different shapes (i.e., triangular, square, octagonal, etc.). In various embodiments, patterned portion 538, and particularly recessed portion 542, includes a hexagonal pattern. In other embodiments, the depressions or recessed sections 542 of the patterned portion 538 are differently shaped (i.e., triangular, square, octagonal, polygonal, etc.).

In a particular embodiment, a recessed vent 546 is positioned within recessed section 542. The recessed vent 546 extends through the housing 512 to provide fluid communication between the cavity 522 and ambient air proximate to the exterior surface 518 of the housing 512. Applicants believe that by locating recessed vent holes 546 within recessed section 542 (and located lower/closer to the wearer's head than outer surface 41 of protruding structure 40), airflow is improved.

In various embodiments, the housing 512 further includes one or more recesses 544. The recess 544 is positioned between the crown 524 and the opposite side portions 532 of the housing 512. In such an embodiment, the recessed portion 544 is recessed lower (i.e., closer to the wearer's head) than both the protruding structures 540 of the patterned portion 538 and the recessed central region 542.

In various embodiments, the housing 512 includes one or more beveled surfaces or sloped surfaces 560. The chamfer 560 is coupled to and extends from one or more side surfaces 562 of the protruding structure 540. Applicants believe that the chamfer 560 generally reduces and/or prevents the outer shell 512 and the crash cap from catching or catching on objects while the user is wearing the crash cap. In various embodiments, chamfer 560 has a smooth surface.

In various embodiments, one or more ramps 560 are coupled to the exterior surface 518 of the housing 512 and extend upward toward the patterned portion 538 and/or the crown 524. In particular embodiments, one or more ramps 560 extend upwardly at an angle from one or more of the opposing side portions 532 toward the crown 524. In other words, the lowest portion of the chamfer (i.e., closest to the outer surface 518) is located adjacent to the side portion 532, and the highest portion of the chamfer 560 (i.e., farther from the outer surface 518) is located adjacent to the crown 524.

It is to be understood that the drawings illustrate exemplary embodiments in detail, and that the application is not limited to the details or methods set forth in the description or illustrated in the drawings. It is also to be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, the description is to be construed as illustrative only. The constructions and arrangements shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) may be made without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number or position of discrete elements may be altered or varied. The order or sequence of any process, logic algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present inventions.

For the purposes of this disclosure, the term "coupled" means that two components are directly or indirectly coupled to each other. Such coupling may be fixed in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional members being attached to one another. Such coupling may be permanent in nature or alternatively may be removable or releasable in nature.

Although the application has been described in the appended claims with a particular combination of features, different embodiments of the application relate to any combination of any features described herein (whether or not such combination is presently claimed) and any such combination of features may be claimed in the application or in future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

In various exemplary embodiments, the relative dimensions (including angle, length, and radius) shown in the figures are proportional. Actual measurements on the drawings will reveal the relative dimensions, angles, and proportions of the various exemplary embodiments. The different exemplary embodiments extend to various ranges surrounding the absolute and relative dimensions, angles, and proportions that may be determined from the figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the figures. Further, the actual dimensions not explicitly stated in the present specification may be determined by using the ratio of the measured dimensions in the drawings in combination with the explicit dimensions stated in the present specification.

Claims (20)

1. A protective cap, the protective cap comprising:

a housing, the housing comprising:

an exterior surface comprising:

a patterned portion configured to engage an inner surface of a headgear covering the headgear;

An interior surface defining a cavity sized to receive a head of a user;

a crown portion configured to cover a portion of the user's head; and

A bottom section defining a lower circumference of the housing; and

An impact absorbing liner positioned within the shell and engaged with an interior surface of the shell.

2. The protective cap of claim 1, wherein the patterned portion extends along the crown portion between a front portion and a rear portion of the outer shell.

3. The protective cap of claim 1, the patterned portion comprising:

a protruding structure extending away from the outer surface; and

A recessed section recessed relative to the protruding structure.

4. The protective cap of claim 3, wherein the patterned portion is a hexagonal pattern.

5. The protective cap of claim 3, further comprising one or more vent holes positioned on the recessed section, the vent holes extending through the housing between the inner surface and the outer surface to provide fluid communication between the cavity and ambient air proximate the outer surface of the housing.

6. The protective cap of claim 1, further comprising ramps coupled to the outer shell and extending upward from an exterior surface of the outer shell toward the patterned portion.

7. The protective cap of claim 1, wherein the patterned portion resists relative rotation between the headgear and the outer shell when the patterned portion engages an inner surface of the headgear.

8. The protective cap of claim 1, further comprising one or more grooves defined in the outer shell extending from the bottom section toward the crown portion.

9. The protective cap of claim 8, wherein the one or more slots are vertical slots positioned on a front portion or a rear portion of the housing.

10. A crash cap, the crash cap comprising:

a housing, the housing comprising:

an exterior surface comprising a patterned portion;

An interior surface defining a cavity sized to receive a head of a user;

a crown portion configured to cover a portion of the user's head;

a bottom section defining a lower circumference of the housing;

a front portion;

A rear portion opposite the front portion;

A pair of side portions extending downwardly from the crown portion and positioned between the front portion and the rear portion; and

An adjustable section extending along a bottom section of each of the pair of side portions, the adjustable section including a shoulder extending along a longitudinal axis of the crash cap; and

An impact absorbing liner positioned within the shell and coupled to an interior surface of the shell.

11. The crash cap of claim 10, wherein the shoulder provides a transition between a thick section of the shell and a thin section of the shell.

12. The crash cap of claim 11, wherein the thick section has a first thickness and the thin section has a second thickness, and wherein the first thickness is greater than the second thickness.

13. The crash cap of claim 11, wherein the shoulder is a stepped transition between a thick section of the shell and a thin section of the shell.

14. The crash cap of claim 10, the patterned portion comprising:

a protruding structure extending away from the outer surface; and

A recessed section positioned on the protruding structure and recessed relative to the protruding structure.

15. The crash cap of claim 10, further comprising one or more vertical slots defined in the shell, the vertical slots positioned on at least one of the front portion and the rear portion, wherein the vertical slots extend from the bottom section toward the crown portion.

16. The crash cap of claim 10, wherein the outer shell is formed of a rigid polymeric material and the impact absorbing liner is formed of a polymeric foam material.

17. A crash cap, the crash cap comprising:

a housing, the housing comprising:

A crown portion configured to cover a portion of a user's head;

a bottom section defining a lower circumference of the housing;

An outer surface;

A plurality of protruding structures extending away from the exterior surface; and

A plurality of recessed sections, each recessed section positioned within one of the plurality of protruding structures and recessed relative to the protruding structure;

An interior surface defining a cavity sized to receive the head of the user; and

An impact absorbing liner positioned within the shell and engaged with an interior surface of the shell.

18. The crash cap of claim 17, further comprising an adjustable section extending along a bottom section of the shell, wherein the adjustable section comprises a step, and wherein the step provides a transition between a thick portion of the shell and a thin portion of the shell.

19. The crash cap of claim 17, wherein each of the plurality of recessed sections has a polygonal shape.

20. The crash cap of claim 17, further comprising one or more grooves defined in the shell, the grooves extending from the bottom section toward the crown portion.