NZ525927A

NZ525927A - Headgear

Info

Publication number: NZ525927A
Application number: NZ52592703A
Authority: NZ
Inventors: Richard Andrew Cathro; Miles Digby Rapley; John Rex Dench
Original assignee: Protective Sports Apparel Ltd
Priority date: 2003-05-16
Filing date: 2003-05-16
Publication date: 2005-12-23
Also published as: AU2004202011A1; GB2401531A; GB2401531B; GB0410836D0

Abstract

Headgear constructed substantially of resilient material, having an inner surface and an outer surface and a plurality of apertures through the resilient material providing conduits between the inner surface and the outer surface, wherein the inner surf has a plurality of channels provided therein are arranged to effect ventilation around a user's head, at least some of the channels communicating with at least some of the apertures.

Description

<div class="application article clearfix" id="description"> 5259 iNTELLECTUAL PROPERTY OFFICE OF N.Z. 1 1 MAY 2004 RECEIVED Patents Form No. 5 OurRef: GL218684 NEW ZEALAND PATENTS ACT 1953 Complete After Provisional No. 525927 Filed: 16 May 2003 COMPLETE SPECIFICATION HEADGEAR AND METHOD OF CONSTRUCTION We, PROTECTIVE SPORTS APPAREL LIMITED, a New Zealand company of 124 Gladstone Road, Mosgiel, Dunedin, New Zealand hereby declare the invention, for which We pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: PT054019190 100372601_1 won 2 HEADGEAR AND METHOD OF CONSTRUCTION FIELD OF THE INVENTION 5 The invention relates to headgear for the protection of a user's hs£d. In particular, the invention relates to headgear useful for protecting the head of a/participant in sports and other activities where physical contact between participants js possible op4ven likely. 10 BACKGROUND 15 Headgear made from a soft material are used extensively tc/protect the heads of players of contact sports. For example, headgeayrs commonly used by wrestlers and rugby players. However, the physical nature^Df these activities can make the wearing of headgear uncomfortable due to pooyventilation of the head and the corresponding loss of cooling. Even in headgear with apertures designed to increase ventilation small apertures alone provide only lipped ventilation over a small area of the user's head. In non-contact sportsvtuch as cycling, headgear made from hard materials with 20 improved ventilationis well-knowa Cycle helmets commonly use speed through the air to assist air to circulate throu^n the helmet. 25 Known headgear that are constructed of a soft or resilient material so that they fit snugly with thyriead of a u£er tend to suffer from ventilation difficulties. Is an objecr of the invention to provide a headgear that overcomes the disadvantages of knownifeadgear, or to at least provide a useful choice. 30 SJATEMENTS OF INVENTION y In a first aspect, the invention provides headgear constructed substantially of resilient material, having an inner surface and an outer surface and a plurality of apertures through the resilient material providing conduits between the inner surface and the outer m »*[«? 2 HEADGEAR AND METHOD OF CONSTRUCTION FIELD OF THE INVENTION 5 The invention relates to headgear for the protection of a user's head. In particular, the invention relates to headgear useful for protecting the head of a participant in sports and other activities where physical contact between participants is possible or even likely. 10 BACKGROUND Headgear made from a soft material are used extensively to protect the heads of players of contact sports. For example, headgear is commonly used by wrestlers and rugby players. However, the physical nature of these activities can make the wearing of 15 headgear uncomfortable due to poor ventilation of the head and the corresponding loss of cooling. Even in headgear with apertures designed to increase ventilation small apertures alone provide only limited ventilation over a small area of the user's head. In non-contact sports, such as cycling, headgear made from hard materials with 20 improved ventilation is well-known. Cycle helmets commonly use speed through the air to assist air to circulate through the helmet. Known headgear that are constructed of a soft or resilient material so that they fit snugly with the head of a user tend to suffer from ventilation difficulties. 25 It is an object of the invention to provide a headgear that overcomes the disadvantages of known headgear, or to at least provide a useful choice. STATEMENTS OF INVENTION 30 In a first aspect, the invention provides headgear constructed substantially of a single layer of moulded resilient material, having no inner rigid layer or rigid outer layer, where the single layer has an inner surface and an outer surface and a plurality of apertures m Mr surface, wherein the inner surface has a plurality of channels provided therein arranged to effect ventilation around the user's head, at least some/of the ctrannels communicating with at least some of the apertures. 10 In a second aspect, the invention provides a method /f constructing headgear, comprising the steps of moulding a top portion formed of resilient material between first moulds; moulding a bottom portion formed of resilient ryfaterial between second moulds; wherein internal channels are formed in the top and/or bottom portions; creating conduits from an inner surface to an outer surface, at least/some of sai^T conduits communicating with at least some of the internal channels; apa joining thpaop and bottom portions to form the headgear. 15 In a third aspect, the invention provides a method of constructing headgear, comprising forming a shell of resilient material Waving internal channels and conduits from an inner surface to an outer surface, at least some of/the conduits communicating with at least some of the internal channels., BRIEF DESCRIPTION OF DRAWING^ 20 The invention will ip described l?y way of example with reference to the accompanying drawings, in whig Figure 1 is/ perspective/lew of headgear according to the invention; 25 Figurf/2 is a top vi^iv of the headgear of Figure 1 30 igure 3 is a back view of the headgear of Figure 1; Figure 4js a second perspective view of the headgear of Figure 1; / / Figure 5A is a first view of a circular aperture and a teardrop shaped depression in the outer surface of the headgear of Figure 1; 3 through the resilient material providing conduits between the inner surface and the outer surface, wherein the inner surface has a plurality of channels moulded therein arranged to effect ventilation around the user's head, at least some of the channels communicating with at least some of the apertures. 5 In a second aspect, the invention provides a method of constructing headgear, comprising the steps of moulding a top portion formed of resilient material between first moulds; moulding a bottom portion formed of resilient material between second moulds; wherein internal channels are formed in the top and/or bottom portions; creating conduits 10 from an inner surface to an outer surface, at least some of said conduits communicating with at least some of the internal channels; and joining the top and bottom portions to form the headgear. In a third aspect, the invention provides a method of constructing headgear, comprising 15 forming a single layer shell of resilient material having internal channels and conduits from an inner surface to an outer surface using a moulding process, at least some of the conduits communicating with at least some of the internal channels. BRIEF DESCRIPTION OF DRAWINGS 20 The invention will be described by way of example with reference to the accompanying drawings, in which: Figure 1 is a perspective view of headgear according to the invention; 25 Figure 2 is a top view of the headgear of Figure 1; Figure 3 is a back view of the headgear of Figure 1; 30 Figure 4 is a second perspective view of the headgear of Figure 1; Figure 5A is a first view of a circular aperture and a teardrop shaped depression in the outer surface of the headgear of Figure 1; 4 Figure 5B is a first section through the aperture and depression of Figure 5A; Figure 5C is a second section through the aperture and depression of Figure 5A; 5 Figure 6A is a first vieyv of a slot shaped aperture and an elongate depression in the outer surface of the headgear of Figure 1; Figure 6B is a first section through the aperture and depression of Figure 6A; 10 Figure 6C is a second section through the aperture and depression of Figure 6A; Figure 7 is an external pattern view of the bottom portion of the headgear of Figure 1; Figure 8 is an internal pattern view of the bottom portion of the headgear of Figure 1; 15 Figure 9 is an external pattern view of the top portion of the headgear of Figure 1; and Figure 10 is an internal pattern view of the top portion of the headgear of Figure 1. 20 DETAILED DESCRIPTION Referring now to Figure 1, the headgear 100 is formed from two pieces, a top portion 101 and a bottom portion 102. The top portion 101 and the bottom portion 102 are stitched together along join 120. The headgear 100 has an inner surface 103 and an 25 outer surface 104. The headgear 100 is constructed substantially of resilient material. The bottom portion 102 includes ear apertures 150 and a chinstrap 151 for retaining the headgear on the head during use. Preferably, the chinstrap 151 uses a Velcro fastening, although other fastenings may also be suitable. Each ear aperture 150 may 30 consist of a single hole of a suitable shape or a number of holes of a suitable shape. For example, in Figure 1, each ear aperture 150 consists of a number of slots. 5 The top portion 101 comprises a central region 111 with five radiating flaps 110, as will be described more fully below. Although a construction utilising 5 flaps is preferred it will be appreciated that different numbers of flaps may be employed. 5 The headgear also includes a plurality of apertures 130, 140 which pass through the headgear, forming conduits from the inner surface to the outer surface. Each of the apertures 130, 140 has an opening to the inner surface 103 and an opening to the outer surface 104. 10 The apertures 130 are slot shaped, and preferably the outer surface openings 133 thereof are situated within elongate, generally parallel-sided depressions 131 in the outer surface 104. The apertures 140 are circular in cross-section, and preferably the outer surface openings 143 thereof are situated within teardrop shaped depressions 141. Many other shapes of aperture and depression may be suitable. Also, apertures 15 with outer surface openings that are not situated within depressions are within the scope of the invention. The apertures communicate with channels in the inner surface of the headgear, as will be described below. Figure 2 shows a top view of the headgear of Figure 1. The top portion of the headgear, 20 as described above, comprises a central region 111 with five radiating flaps 110. The flaps 110 are separated by slits 210 and 220. The slits 210 are defined by slit edges 211 and 212, which end at join 120, while the slit 220, defined by slit edges 221 and 222, extends to the bottom of the headgear. Preferably, the width of the slit 220 can be adjusted by loosening or tightening a lacing arrangement 240 such that the 25 circumference 230 of the headgear can be altered. In this way the headgear can be adjusted to the size of the head of a user. Other methods of joining the sides of the slit may also be suitable. For example, a Velcro type fastening or an elastic arrangement could also be used. Here we take the circumference to include the width of the slit 220 along the lacing arrangement 240. 30 Figure 3 shows a rear view of the headgear of Figure 1. The lacing arrangement 240 consists of a lace 320 passed through a plurality of holes 310 in sections 331 and 332 adjacent to the slit edges 221 and 222. 6 10 15 Figure 4 is another view of the headgear of Figure 1. In Figure 4 the internal channelling of the headgear is visible. A number of channels 410 are formed on the inner surface 103. The inner surface openings 132, 142 (shown in Figures 5B, 5C, 6B and 6C) of apertures 130, 140 communicate with channels on the inner surface 103. Preferably, the inner surface openings 132, 142 of apertures 130 and 140 are situated within the channels 410 on the inner surface. The inner surface openings could also be situated partially within the channels on the inner surface or directly adjacent to the channels on the inner surface. In Figure 4, the headgear 100 is shown with the chinstrap 151 disengaged. To engage the chinstrap 151, the end 152 of the chinstrap 151 is passed through the aperture 420. The chinstrap 151 is than doubled back upon itself and secured using a Velcro fastening 153 (not visible in Figure 4). Figure 5A shows a first view of one of the teardrop depressions 141 with a circular aperture 140, of the headgear 100 of Figure 1. Figure 5B shows a first section through the headgear along the line B-B shown in Figure 5A. The outer surface opening 143 of a circular aperture 140 is situated within a teardrop shaped depression 141 in the outer 20 surface 104. The aperture 140 passes through the resilient material 105 and its inner surface opening 142 is situated within channel 410 in the inner surface 103. Figure 5C shows a second section through the headgear, along the line C-C shown in Figure 5A. Figure 6A shows a first view of one of the elongate, generally parallel-sided depressions 25 131 with a slot shaped aperture 130, of the headgear 100 of Figure 1. Figure 6B shows a third section through the headgear along the line D-D shown in Figure 6A. The outer surface opening 133 of the aperture 130 is situated within an elongate depression 131 in the outer surface 104. The aperture 130 passes through the resilient material 105 and its inner surface opening 132 is situated within channel 410 in the inner surface 103. 30 Figure 6C shows a fourth section through the headgear along the line E-E shown in Figure 6A. 7 Preferably, the depressions 131 and 141 have lengths which are within the range 20 to 60 mm, ideally about 40 mm. Preferably, the depressions 131 and 141 have widths in the range 5 to 30 mm, ideally about 15 mm. 5 Preferably, each slot shaped aperture 130 is situated substantially centrally within an elongate depression 131 and each circular aperture 140 is situated towards the wider end of a teardrop shaped depression 141. Preferably, the circular apertures 140 have diameters in the range 5 to 15 mm, ideally about 9 mm. 10 Preferably the slot shaped apertures 130 have lengths in the range 15 to 45mm, ideally about 25 mm and widths in the range 2 to 20 mm, ideally about 3 mm. The apertures 130 and 140 act as inlet apertures or exhaust apertures. The depressions in the outer surface are shaped such that air flow at the outer surface 15 causes a pressure difference at the outer surface openings of the apertures relative to the pressure within the channels. Airflow at the outer surface could be caused either by wind or by movement of the headgear through the air. Thus, air tends to circulate through the apertures because of the pressure difference. When the airflow at the outer surface is substantially perpendicular to the outer surface, this airflow will tend to push 20 air through the apertures and into the channels. When the airflow is substantially parallel to the outer surface air may tend to be drawn from the channels towards the outer surface. These effects encourage circulation within the channels, and effect ventilation around the user's head. The apertures should sufficiently allow circulation of the air, whilst not reducing protection of the user's head. 25 Figure 7 shows a pattern view of the outer surface of the bottom portion 102 of headgear of Figure 1, showing the teardrop shaped depressions 141 and the ear apertures 150. The chinstrap .151 and the apertures 140 are not shown. Figure 8 shows a similar pattern view of the inner surface of the bottom portion of the headgear of Figure 1, 30 showing the channels 410 and the ear apertures 150. Figure 9 shows a pattern view of the outer surface of the top portion 101 of the headgear of Figure 1, showing teardrop shaped depressions 141 and elongate depressions 131. 8 Figure 10 shows a pattern view of the inner surface of the top portion of the headgear of Figure 1, showing the channels 410. Preferably, the resilient material comprising the top and bottom portions of the headgear 5 is resilient foam, although other materials such as leather, for example, may be suitable. Ideally, ethyl vinyl acetate (EVA) or polyethylene closed cell foam is used, since they provide greater comfort than most other resilient materials. Alternatively, a gel-filled material could be used. For example, closed cell foam sheets of about 2 mm thickness could be joined together with gel bladders between them, or gel could be injected 10 between two closed cell foam sheets. Rubber or plastic sheets could also be used in place of the closed cell foam sheets. The resilient material may have a density of between 30 and 100 kg per cubic metre, preferably within the range 30 to 60 kg per cubic metre, ideally about 45 kg per cubic 15 metre. The resilient material may have a thickness of between 5 and 20 mm, preferably in the range 8 to 12 mm. An inner fabric layer may be fixed to the inner surface of the headgear and an outer fabric layer may be fixed to the outer surface of the headgear. Preferably, the fabrics 20 used should not be significantly affected by sunlight, water, dirt, sweat, soaps or detergents. Ideally, the inner fabric is cotton or a similar fabric for maximum comfort and sweat dissipation and the outer fabric is nylon or lycra for maximum UV resistance, wear and colour fastness. 25 The headgear described above can conveniently be made by thermo moulding. Moulding in two dimensions, as required by the present design, is more difficult than moulding in only one dimension. In the preferred process, closed cell foam laminated on one side with nylon or lycra and on the other side with cotton, and having a thickness of about 15 mm is moulded between at least two moulds, at high temperature. The closed 30 cell foam may be provided to the moulding stage in sheet form. The moulds may be made of wood, an alloy or another suitable material. 9 The fabric layers can be attached to the closed cell foam either by adhesion or heat bonding, although other methods of attachment may also be suitable. After the moulding, the closed cell foam should ideally have a thickness of around 10 mm. The channels, depressions and apertures are created by the shape of the moulds. 5 Alternatively, the apertures could be created by punching after the moulding process. The edges of the headgear or of the portions of the headgear can be defined by cutting during the moulding process, where the moulds include cutting edges, or before or after the moulding process. 10 Preferably, the top and bottom portions of the headgear are moulded separately and are then joined, preferably by stitching, although other methods of joining may also be suitable. The headgear could also be made by injection moulding, either in a single piece or in a 15 number of portions. In this case cutting to shape may not be necessary. Preferably a slightly elastic material would be used if the headgear were made in a single piece, so that adjustment means would be unnecessary. Headgear according to the invention is suitable for use in many sports. For example, the 20 headgear could be worn by players of rugby union, rugby league, Australian Rules football and Gaelic football and by windsurfers, surfers, and kite-surfers. In some cases, the headgear worn in a particular sporting code must meet regulations imposed by a governing body, and it is anticipated that headgear according to the invention could be made from a variety of materials, materials of different thicknesses etc. in order to meet 25 these requirements. While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention of the Applicant to restrict or in anyway limit the scope of the appended claims to such 30 detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and method, and illustrative example shown and described. 10 Accordingly, departures may be made from such details without departure from the spirit or scope of the Applicant's general inventive concept. ill y j'r'1,1 11 CLAIMS 10 Headgear constructed substantially of resilient material, having an/inner surface and an outer surface and a plurality of apertures through the resilient material providing conduits between the inner surface and the outer surface, wherein the inner surface has a plurality gn channels provided therein arranged to effect ventilation around a user's head, at/least some of the channels communicating with at least some of the apertures. Headgear as claimed in claim 1. Wherein each A the apertures has an inner surface opening, and at leagt some of we inner surface openings are situated at least partly within channels in^ne inner surface. Headgear as ciaim yd in claim 1 erf claim 2, wherein each of the apertures has an outer sun; ce opening and at least some of the outer surface openings ar^situated at /feast partially within depressions in the outer surface. H< [gear as damned in claim 3, wherein at least some of the outer surface Denings are situated entirely within the depressions in the outer surface. Headgear as claimed in claim 3 or claim 4, wherein at least some of the depressions are elongate. Headgear as claimed in any one of claims 3 to 5, wherein at least some of the depressions are tear-drop shaped. Headgear as claimed in any one of claims 3 to 6, wherein at least some of the outer surface openings situated within depressions are situated towards the rear of the depressions with respect to the forward direction of the headgear in use. 11 </div>

Claims

<div class="application article clearfix printTableText" id="claims"> CLAIMS

1. Headgear constructed substantially of a single layer of moulded resilient material, having no inner rigid layer or outer rigid layer, where the single layer has an inner surface and an outer surface and a plurality of apertures through the resilient material providing conduits between the inner surface and the outer surface, wherein the inner surface has a plurality of channels moulded therein arranged to effect ventilation around a user's head, at least some of the channels communicating with at least some of the apertures,

2. Headgear as claimed in claim 1, wherein each of the apertures has an inner surface opening, and at least some of the inner surface openings are situated at least partly within channels in the inner surface.

3. Headgear as claimed in claim 1 or claim 2, wherein each of the apertures has an outer surface opening, and at least some of the outer surface openings are situated at least partially within depressions in the outer surface.

4. Headgear as claimed in claim 3, wherein at least some of the outer surface openings are situated entirely within the depressions in the outer surface.

5. Headgear as claimed in claim 3 or claim 4, wherein at least some of the depressions are elongate.

6. Headgear as claimed in any one of claims 3 to 5, wherein at least some of the depressions are tear-drop shaped.

7. Headgear as claimed in any one of claims 3 to 6, wherein at least some of the outer surface openings situated within depressions are situated towards the rear of the depressions with respect to the forward direction of the headgear in use. 12

8. Headgear as claimed in any one of claims 3 to 7, wherein a depression forms a catchment area, such that air flow over the outer surface creates a pressure difference between the inner and outer surface openings of a conduit. 5

9. Headgear as claimed in any one of the preceding claims, wherein at least some of the apertures are circular in cross-section.

10. Headgear as claimed in claim 9, wherein the apertures which are circular in 10 cross-section are situated in tear-drop shaped depressions in the outer surface.

11. Headgear as claimed in claim 9 or claim 10, wherein the apertures which are circular in cross-section have diameters in the range 5 to 15 mm. 15

12. Headgear as claimed in claim 12, wherein the apertures which are circular in cross-section have diameters of about 9 mm.

13. Headgear as claimed in any one of the preceding claims, wherein at least 20 some of the apertures are slots.

14. Headgear as claimed in claim 13, wherein the slots are situated within elongate substantially parallel-sided depressions in the outer surface. 25

15. Headgear as claimed in claim 14, wherein the elongate substantially parallel-sided depressions have lengths in the range 20 to 60 mm and widths in the range 5 to 30 mm.

16. Headgear as claimed in claim 15, wherein the elongate substantially paraliel-30 sided depressions have lengths of about 40 mm and widths of about 15 mm.

17. Headgear as claimed in claim 13 or claim 14, wherein the slots have lengths of about 25 mm and widths of about 3 mm. 13

18. Headgear as claimed in any one of the preceding claims, formed substantially from two pieces of resilient material. 5

19. Headgear as claimed in claim 18, wherein the two pieces are a top portion and a bottom portion.

20. Headgear as claimed in claim 19, wherein the top portion comprises a central region and a plurality of radiating flaps. 10

21. Headgear as claimed in claim 20, comprising five radiating flaps.

22. Headgear as claimed in any one of the preceding claims, wherein the headgear includes means for adjusting the circumference of the headgear. 15

23. Headgear as claimed in claim 22, wherein a vertical split is provided at the back of the headgear and the means for adjusting the circumference comprises a means for adjusting the width of the split. 20

24. Headgear as claimed in claim 23, wherein the means for adjusting the width of the split comprises a lacing arrangement.

25. Headgear as claimed in any one of the preceding claims, wherein the resilient material is resilient foam. 25

26. Headgear as claimed in any one of the preceding claims, wherein the resilient material is less than 12 millimetres thick.

27. 30 Headgear as claimed in any one of the preceding claims, wherein an inner fabric layer is attached to the inner surface and an outer fabric layer is attached to the outer surface of the headgear. 14

28. Headgear as claimed in ciaim 27, wherein the resilient material and fabric layers together are less than 13 millimetres thick.

29. Headgear as claimed in claim 28, wherein the resilient material and fabric 5 layers together are less than 10 millimetres thick.

30. Headgear as claimed in any one of the preceding claims, wherein the resilient material has a density of less than 60 kilograms per cubic metre. 10

31. Headgear as claimed in claim 30, wherein the resilient material has a density of less than 45 kilograms per cubic metre.

32. A method of protecting the head of a user, comprising the wearing of headgear as claimed in any one of claims 1 to 31. 15

33. A method of constructing headgear, comprising the steps of: a) moulding a top portion formed of resilient material between first moulds; 20 b) moulding a bottom portion formed of resilient material between second moulds; wherein internal channels are formed in the top and/or bottom portions; 25 c) creating conduits from an inner surface to an outer surface, at least some of said conduits communicating with at least some of the internal channels; and 30 d) joining the top and bottom portions to form the headgear.

34. A method as claimed in claim 33, wherein the resilient material is in sheet form.

35

36.

37.

38.

39.

40.

41.

42.

43.

44. 15 A method as claimed in claim 33 or claim 34, wherein the conduits are formed by punching apertures in the resilient material. A method as claimed in claim 33 or 34, wherein the conduits are formed during moulding of the top and bottom portions. A method as claimed in any one of claims 33 to 36, wherein during moulding depressions are formed in the outer surface. A method as claimed in claim 37, wherein each conduit has an outer surface opening and the outer surface openings of at least some of the conduits are situated within depressions in the outer surface. A method as claimed in any one of claims 33 to 38, wherein the top and bottom portions are cut to shape. A method as claimed in claim 39, wherein the cutting of the top and bottom portions to shape is performed during moulding of the top and bottom portions. A method as claimed in any one of claims 33 to 40, wherein the top and bottom portions are joined by stitching. A method as claimed in any one of claims 33 to 41, wherein the resilient material is closed cell foam. A method as claimed in claim 42, wherein the closed cell foam is ethyl vinyl acetate foam. A method as claimed in claim 42, wherein the closed cell foam is polyethylene closed cell foam. ffci: 16

45. A method as claimed in any one of claims 33 to 44, wherein £Ke moulding performed using a thermo moulding process. 46. A method of constructing headgear claimed in anyyfne of claims' 1 to 17, wherein the headgear is formed substantially in ar single piece/by injection moulding. 10 15 20 47. A method of constructing headgear, comprising forming a shell of resilient material having internal channels and/conduits fron/an inner surface to an outer surface, at least some of thp conduits c$>mmunicating with at least some of the internal channels. A method as claimed in cl^im 47, whecJn the shell of resilient material is formed by injection mouL Headgear substantially as herein 'described with reference to Figures 1 to 10 of the drawings^ 50. A method/of construt fg headgear substantially as herein described with reference to Figures/ 10 of the drawings. 25 PROTECTIVE SPORTS APPAREL LIMITED By its Attorneys BALDWIN SHELSTON WATERS 16

46. 5

47. 10

48. 15

49.

50. 20 A method as claimed in any one of claims 33 to 44, wherein the moulding is performed using a thermo moulding process. A method of constructing headgear claimed in any one of claims 1 to 17, wherein the headgear is formed substantially in a single piece by injection moulding. A method of constructing headgear, comprising forming a single layer shell of resilient material having internal channels and conduits from an inner surface to an outer surface using a moulding process, at least some of the conduits communicating with at least some of the internal channels. A method as claimed in claim 47, wherein the shell of resilient material is formed by injection moulding. Headgear substantially as herein described with reference to Figures 1 to 10 of the drawings. A method of constructing headgear substantially as herein described with reference to Figures 1 to 10 of the drawings. 25 30 By its Attorneys BALDWIN SHELSTON WATERS </div>