A fall-resistant hooded outdoor garment and method of manufacture

Abstract

This invention discloses a fall-proof head-protecting outdoor garment and its manufacturing method, relating to the field of outdoor clothing technology. The garment includes a main body, comprising at least a torso, sleeves, and a hood connected to the torso. The garment is characterized by having multiple composite protective structures embedded in the back of the hood, the shoulders of the torso, and the elbows of the sleeves. Each composite protective structure includes a passive cushioning layer and an active protective layer. It possesses a dynamic protection system with passive cushioning and active enhancement: the embedded passive cushioning layer provides basic daily protection, while the active protective layer, intelligently triggered by a sensor network, rapidly inflates upon detecting a fall, forming an air cushion that envelops key areas, dispersing and absorbing localized impact force over a large area, significantly reducing the risk of serious injury to the head, shoulders, joints, etc.

Description

Technical Field

[0001] This invention relates to the field of outdoor clothing technology, specifically to a shockproof head-protecting outdoor garment and its manufacturing method. Background Technology

[0002] With the increasing popularity of outdoor sports such as mountaineering, hiking, and cycling, participants face growing personal safety risks, particularly the risk of falls and injuries. The back of the head, shoulders, and elbows are particularly vulnerable to severe impacts during falls, potentially leading to concussions, fractures, and other injuries.

[0003] Currently, outdoor protective gear on the market suffers from the following limitations: First, a conflict between rigid protection and comfort: While common rigid protective gear (such as helmets and elbow pads) offers good protection, they are bulky, heavy, and inconvenient to carry. Furthermore, they are separate from clothing, affecting flexibility and wearing comfort, leading to low user willingness to wear them or reluctance to wear them during non-high-intensity activities, creating a safety gap. Second, limitations of passive protection: Some outdoor clothing incorporates cushioning materials such as foam or gel, but their protective capabilities are fixed and cannot dynamically enhance against the high-energy impact of a fall, resulting in limited protective effectiveness. Third, low levels of intelligence: Existing technology lacks real-time, accurate monitoring and proactive response capabilities for user posture. Some intelligent safety equipment, such as smart helmets, have limited functionality and do not form a systematic, integrated protective solution with clothing, resulting in poor coordination between different protective points.

[0004] Therefore, there is an urgent need to develop outdoor clothing that integrates comfort, concealment, high protection, and intelligent active response, providing seamless protection during daily wear and activating immediately when danger occurs, providing cushioning protection for core areas that surpasses conventional passive protection. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the above-mentioned technology by providing a shockproof head-protecting outdoor garment and its manufacturing method.

[0006] To achieve the above objectives, the present invention provides a protective headgear for outdoor wear and a method for manufacturing the same, comprising a garment body, wherein the garment body includes at least a torso, sleeves, and a hood connected to the torso, characterized in that: The garment body is provided with multiple composite protective structures, which are respectively embedded in the back of the head of the hat, the shoulders of the torso, and the elbow joints of the sleeves; the composite protective structure includes a passive cushioning layer and an active protective layer; The passive buffer layer is an impact-resistant protective sheet that conforms to an ergonomic shape, comprising a buffer matrix made of energy-absorbing material and an impact-resistant surface layer composited on the outside of the buffer matrix. The active protective layer is an inflatable airbag module disposed between or on the side of the passive buffer layer and the main fabric of the garment. It includes at least one inflatable airbag, a gas generator connected to the airbag, a sensor network for detecting abnormal human posture, and a control unit; the airbag is filled with fluff. The sensor network includes at least an accelerometer and a gyroscope located inside the cap, and a center of gravity sensor located at the lower hem of the torso; The control unit controls the gas generator to inflate the airbag under predetermined conditions based on the signal from the sensor network, causing the airbag to expand and form a buffer air cushion covering the outside of the critical protection area; wherein, when the active protection layer airbag is not triggered, it is in a folded or rolled-up state and is fixed in the garment interlayer by high-strength sewing thread at a predetermined stress breaking threshold.

[0007] Preferably, the impact-resistant protective sheet's cushioning matrix is ​​made of either closed-cell foam or silicone, and the impact-resistant surface layer is made of thermoplastic polyurethane, polycarbonate, or high-performance engineering plastic through integral molding.

[0008] Preferably, the airbag is made of a high-toughness elastic fabric coated with an airtight coating and is connected to the garment lining or the passive cushioning layer by the high-strength stitching.

[0009] Preferably, the sensor network further includes a pressure sensor and a humidity sensor; the pressure sensor is integrated into the head contact area inside the hat body to monitor whether the hat body is worn correctly; the humidity sensor is disposed on the inner lining surface of the garment body to monitor the wearer's perspiration; the control unit is connected to a low-power Bluetooth module to send sensor data, airbag status and alarm information to a mobile terminal.

[0010] Preferably, the triggering logic of the control unit is a multi-level judgment mechanism: the first level judgment is based on the body tilt angular velocity and angle threshold detected by the center of gravity sensor; the second level judgment is based on the abnormal head movement trajectory detected by the accelerometer and gyroscope inside the cap; the control unit triggers the gas generator to work only when both judgment conditions are met within a preset time window.

[0011] Preferably, the garment body comprises, from the outside to the inside, an outer functional fabric, a middle waterproof and breathable membrane, and an inner comfort lining; the outer functional fabric is a high-strength nylon or polyester fiber fabric and is coated with a waterproof coating; the composite protective structure is disposed between the middle waterproof and breathable membrane and the inner comfort lining, or is partially embedded in the inner comfort lining.

[0012] Preferably, the gas generator is a miniature high-pressure gas cylinder or a miniature chemical gas generating device, which is connected to the airbag pipeline via a quick connector and installed in a special pocket at the waist or chest of the garment body in the form of a replaceable module.

[0013] As a preferred embodiment, the following manufacturing steps are included: S1: Preparation of composite protective structure: Based on 3D scanning data of key protective areas of the human body, an impact-resistant protective sheet is molded as a passive buffer layer; high-toughness elastic fabric is cut and heat-fused into airbags for each sub-area, with reserved inflation ports; the airbags are pre-fixed to the passive buffer layer or reinforcing lining according to the design layout, and high-strength sewing thread with predetermined parameters is used to constrain and sew along the fold line of the airbag. S2: Integrated sensor and control system: The components of the sensor network are packaged on a flexible circuit board; the electrical interfaces of the packaged sensor modules, control units and gas generators are connected by flexible wires and fixed in a predetermined position in the lining of the garment. S3: Garment Assembly and Composite Structure Implantation: Cut and sew the outer functional fabric, the middle waterproof and breathable membrane, and the inner comfort lining separately to form the basic components of the garment body; position and lay the composite protective structure prepared in step S1 on the inner comfort lining of the torso, sleeves, and hood; connect and seal the sensor control system cable from step S2 to the airbag tubing of the composite protective structure; integrate the composite protective structure, sensor control system, and inner comfort lining into an inner lining module through quilting or partial bonding processes. S4: Assembly and Testing: Combine and sew the integrated inner lining module with the outer fabric with the middle waterproof and breathable membrane to form a complete garment component; install the zipper, adjustment mechanism and the flexible expandable accommodating cavity; conduct airtightness test, sensor calibration and simulated trigger test to ensure that the airbag can be smoothly deployed from the high-strength sewing line constraint as designed and form an effective cushioning air cushion.

[0014] The beneficial effects of this invention are: 1. It has a dynamic protection system with passive buffering and active enhancement: It provides basic daily protection through an embedded passive buffer layer, and combined with an active protection layer that is intelligently triggered by a sensor network, it can quickly inflate and expand at the moment a fall is detected to form an air cushion that wraps around key parts, which disperses and absorbs the local impact force over a large area, greatly reducing the risk of serious injury to the brain, shoulders, joints and other parts.

[0015] 2. The airbags in the active protective layer are folded or rolled up when not triggered and secured with high-strength stitching, resulting in a clean, non-bulky appearance and unrestricted movement. They only deploy in emergency situations triggered within milliseconds, solving the discomfort associated with traditional rigid protective gear.

[0016] 3. By employing a multi-level judgment mechanism and combining it with pressure sensors to monitor the wearing status, it can effectively distinguish between normal strenuous exercise and actual falls, greatly reducing the false trigger rate and ensuring the accuracy and reliability of protective actions.

[0017] 4. The sensors, control unit, and gas generator are highly integrated inside the garment, and the system's stability and maintainability are ensured through flexible circuitry and modular installation. Structurally, the composite protective structure is placed between the functional fabric and the lining, without compromising the garment's basic properties such as waterproofing and breathability.

[0018] 5. Sensor networks can not only be used for fall detection, but also monitor wearing compliance and physiological status. They can also be interconnected with mobile terminals via Bluetooth modules to achieve data recording, alarm sending, and system status monitoring, thus expanding the product's health management functions.

[0019] 6. In the manufacturing process, the protective sheet is molded using 3D scanning data to make it fit the human body better; high-strength sewing thread with predetermined parameters is used to restrain the airbag, ensuring that the airbag is securely stored under normal conditions and can be smoothly broken and deployed when triggered; finally, airtightness and simulated trigger tests are conducted to ensure that the protective performance of the final product is stable and reliable. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram showing the location and structure of the internal components of the present invention.

[0022] In the picture, 1. Torso, 2. Sleeve, 3. Hat, 4. Impact-resistant protective plate, 5. Airbag, 6. Gas generator, 7. Accelerometer, 8. Gyroscope, 9. Center of gravity sensor, 10. Pressure sensor, 11. Humidity sensor, 12. Special pocket. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0024] Reference Figure 1-2This embodiment provides a shockproof head protection outdoor garment and its manufacturing method, including a garment body, the garment body including at least a torso 1, sleeves 2 and a hood 3 connected to the torso 1, the main fabric of the garment body is mainly made of nylon sewing thread; The garment body is provided with multiple composite protective structures, which are respectively embedded in the back of the head of the hat body 3, the shoulder of the torso 1, and the elbow joint of the sleeve 2; the composite protective structure includes a passive cushioning layer and an active protective layer. The passive buffer layer is an ergonomically shaped impact-resistant protective sheet 4, which includes a buffer substrate made of energy-absorbing material and an impact-resistant surface layer composited on the outside of the buffer substrate. The active protective layer is an inflatable airbag module disposed between or on the side of the passive cushioning layer and the main fabric of the garment. It includes at least one inflatable airbag 5, a gas generator 6 connected to the airbag 5, a sensor network for detecting abnormal human posture, and a control unit. The airbag 5 is filled with fluff. When the airbag 5 is not inflated, the fluff can further enhance comfort. When the airbag 5 is inflated, the fluff spreads out without affecting the normal use of the airbag. The sensor network includes at least an accelerometer 7 and a gyroscope 8 located inside the cap 3, and a center of gravity sensor 9 located at the lower hem of the torso 1; The control unit controls the gas generator 6 to inflate the airbag 5 under predetermined conditions according to the signal of the sensor network, so that the airbag 5 expands to form a buffer air cushion covering the outside of the critical protection area; wherein, the airbag 5 of the active protection layer is in a folded or rolled-up state when not triggered, and is fixed in the garment interlayer by high-strength sewing thread at a predetermined stress breaking threshold.

[0025] The impact-resistant protective sheet 4 has a buffer substrate made of either closed-cell foam or silicone, and the impact-resistant surface layer is made of thermoplastic polyurethane, polycarbonate, or high-performance engineering plastic through integral molding.

[0026] The airbag 5 is made of a high-toughness elastic fabric coated with an airtight coating and is connected to the garment lining or the passive cushioning layer by the high-strength stitching.

[0027] The sensor network also includes a pressure sensor 10 and a humidity sensor 11; the pressure sensor 10 is integrated into the head contact area inside the hat body 3 and is used to monitor whether the hat body 3 is worn correctly; the humidity sensor 11 is set on the inner lining surface of the garment body and is used to monitor the wearer's perspiration; the control unit is connected to a low-power Bluetooth module and can send sensor data, airbag 5 status and alarm information to a mobile terminal.

[0028] The triggering logic of the control unit is a multi-level judgment mechanism: the first level judgment is based on the body tilt angular velocity and angle threshold detected by the center of gravity sensor 9; the second level judgment is based on the abnormal head movement trajectory detected by the accelerometer 7 and gyroscope 8 inside the cap 3; the control unit will trigger the gas generator 6 to work only when both judgment conditions are met within a preset time window.

[0029] The garment body comprises, from the outside to the inside, an outer functional fabric, a middle waterproof and breathable membrane, and an inner comfort lining; the outer functional fabric is a high-strength nylon or polyester fiber fabric and is coated with a waterproof coating; the composite protective structure is disposed between the middle waterproof and breathable membrane and the inner comfort lining, or is partially embedded in the inner comfort lining.

[0030] The gas generator 6 is a miniature high-pressure gas cylinder or a miniature chemical gas generating device. It is connected to the airbag 5 pipeline via a quick connector and is installed in a special pocket 12 at the waist or chest of the garment body in the form of a replaceable module.

[0031] As a preferred embodiment, the following manufacturing steps are included: S1: Preparation of composite protective structure: Based on the 3D scanning data of the key protective areas of the human body, the impact-resistant protective sheet 4 is molded as a passive buffer layer; high-toughness elastic fabric is cut and heat-fused into airbags 5 for each sub-area, with reserved inflation ports; the airbags 5 are pre-fixed to the passive buffer layer or reinforcing lining according to the design layout, and high-strength sewing thread with predetermined parameters is used to constrain and sew along the fold line of the airbags 5; S2: Integrated sensor and control system: The components of the sensor network are packaged on a flexible circuit board; the electrical interfaces of the packaged sensor module, control unit and gas generator 6 are connected by flexible wires and fixed in a predetermined position in the garment lining. S3: Garment Assembly and Composite Structure Implantation: Cut and sew the outer functional fabric, the middle waterproof and breathable membrane, and the inner comfort lining separately to form the basic components of the garment body; position and lay the composite protective structure prepared in step S1 on the inner comfort lining of the torso, sleeves 2, and hood 3; connect and seal the sensor control system cable from step S2 to the airbag 5 tubing of the composite protective structure; integrate the composite protective structure, sensor control system, and inner comfort lining into an inner lining module through quilting or partial bonding processes; S4: Assembly and Testing: Combine and sew the integrated inner lining module with the outer fabric with the middle waterproof and breathable membrane to form a complete garment component; install the zipper, adjustment mechanism and the flexible expandable accommodating cavity; conduct airtightness test, sensor calibration and simulated trigger test to ensure that the airbag 5 can be smoothly deployed from the high-strength sewing line constraint as designed and form an effective cushioning air cushion.

[0032] A sensor network distributed across key parts of the garment, including an accelerometer 7 and a gyroscope 8 inside the hat body 3, a center of gravity sensor 9 at the torso hem, a pressure sensor 10 inside the hat, and a humidity sensor 11 in the lining, operates continuously. The accelerometer 7 and gyroscope 8 monitor changes in the linear acceleration and angular velocity of the head; the center of gravity sensor 9 monitors body posture and tilt angular velocity; and the pressure sensor 10 confirms whether the hat body 3 is worn correctly.

[0033] The control unit receives and processes sensor data in real time. Its built-in multi-level triggering logic begins to operate: First, it determines whether the data from the center of gravity sensor 9 exceeds a preset "body imbalance" threshold, such as a tilt angle greater than 45 degrees and an excessively high angular velocity; second, it simultaneously determines whether the head sensor detects an abnormal movement trajectory consistent with fall characteristics, such as a rapid fall or rotation. Only when both judgment conditions are met within a very short preset time window, such as 200-500 milliseconds, and the pressure sensor 10 confirms that the device is properly fitted, does the control unit determine it as a real fall event requiring protection.

[0034] Once the determination is successful, the control unit immediately sends a trigger command to the gas generator 6. The gas generator 6 is a miniature high-pressure gas cylinder or chemical gas generation device that generates a large amount of gas within milliseconds and rapidly fills the airbag 5 in the target area through pipelines.

[0035] The rapidly expanding airbag 5 generates enough force to instantly break through the high-strength stitching that holds it in place in a folded state. The airbag 5 unfolds from the clothing layer, expanding into a designed cushioning pad that covers the outside of the passive cushioning layer such as the back of the head, shoulders, or elbows. Together with the impact-resistant protective plate 4 below, it forms a three-dimensional, soft energy-absorbing buffer zone that effectively absorbs and disperses impact energy before or immediately upon impact with the ground.

[0036] The entire triggering process and sensor data can be transmitted to the user's mobile terminal, such as a smartphone, via a low-power Bluetooth module for alarm notification, accident information recording, and data support for post-event analysis. The gas generator 6 features a modular design and can be replaced after triggering, restoring the garment's protective capabilities.

[0037] Of course, the above description is not limited to the examples above. Technical features not described in this invention can be implemented by or using existing technology, and will not be repeated here. The above embodiments and drawings are only used to illustrate the technical solutions of this invention and are not intended to limit this invention. This invention has been described in detail with reference to preferred embodiments. Those skilled in the art should understand that any changes, modifications, additions or substitutions made by those skilled in the art within the scope of this invention do not depart from the spirit of this invention and should also fall within the scope of protection of the claims of this invention.

Claims

1. A shockproof head-protecting outdoor garment and its manufacturing method, comprising a garment body, wherein the garment body includes at least a torso (1), sleeves (2), and a hood (3) connected to the torso (1), characterized in that: The garment body is provided with multiple composite protective structures, which are respectively embedded in the back of the head of the hat (3), the shoulder of the torso (1), and the elbow joint of the sleeve (2); the composite protective structure includes a passive buffer layer and an active protective layer. The passive buffer layer is an impact-resistant protective sheet (4) that conforms to the shape of an ergonomic body, which includes a buffer matrix made of energy-absorbing material and an impact-resistant surface layer composited on the outside of the buffer matrix. The active protective layer is an inflatable airbag module disposed between or on the side of the passive buffer layer and the main fabric of the garment. It includes at least one inflatable airbag (5), a gas generator (6) connected to the airbag (5), a sensor network for detecting abnormal human posture, and a control unit; the airbag (5) is filled with fluff. The sensor network includes at least an accelerometer (7) and a gyroscope (8) located inside the cap (3), and a center of gravity sensor (9) located at the hem of the torso (1). The control unit controls the gas generator (6) to inflate the airbag (5) under predetermined conditions according to the signal of the sensor network, so that the airbag (5) expands to form a buffer air cushion covering the outside of the critical protection area; wherein, the airbag (5) of the active protection layer is in a folded or rolled-up state when not triggered, and is fixed in the garment interlayer by high-strength sewing thread at a predetermined stress fracture threshold.

2. The anti-fall head protection outdoor clothing and its manufacturing method according to claim 1, characterized in that, The impact-resistant protective sheet (4) uses one of closed-cell foam material or silicone material as its buffer matrix, and the impact-resistant surface layer is integrally molded using thermoplastic polyurethane, polycarbonate or high-performance engineering plastic.

3. The anti-fall head-protecting outdoor clothing and its manufacturing method according to claim 1, characterized in that, The airbag (5) is made of a high-toughness elastic fabric coated with an airtight coating and is connected to the garment lining or the passive cushioning layer by the high-strength stitching.

4. The anti-fall head protection outdoor clothing and its manufacturing method according to claim 1, characterized in that, The sensor network also includes a pressure sensor (10) and a humidity sensor (11); the pressure sensor (10) is integrated into the head contact area inside the hat body (3) to monitor whether the hat body (3) is worn correctly; the humidity sensor (11) is set on the inner lining surface of the garment body to monitor the wearer's perspiration; the control unit is connected to a low-power Bluetooth module and can send sensor data, airbag (5) status and alarm information to a mobile terminal.

5. The anti-fall head protection outdoor clothing and its manufacturing method according to claim 1 or 4, characterized in that, The triggering logic of the control unit is a multi-level judgment mechanism: the first level judgment is based on the body tilt angular velocity and angle threshold detected by the center of gravity sensor (9); the second level judgment is based on the abnormal head movement trajectory detected by the accelerometer (7) and gyroscope (8) in the cap (3); the control unit will trigger the gas generator (6) to work only when both judgment conditions are met within a preset time window.

6. The anti-fall head-protecting outdoor clothing and its manufacturing method according to claim 1, characterized in that, The garment body comprises, from the outside to the inside, an outer functional fabric, a middle waterproof and breathable membrane, and an inner comfort lining; the outer functional fabric is a high-strength nylon or polyester fiber fabric and is coated with a waterproof coating; the composite protective structure is disposed between the middle waterproof and breathable membrane and the inner comfort lining, or is partially embedded in the inner comfort lining.

7. The anti-fall head protection outdoor clothing and its manufacturing method according to claim 1, characterized in that, The gas generator (6) is a miniature high-pressure gas cylinder or a miniature chemical gas generating device. It is connected to the pipeline of the air bag (5) through a quick connector and installed in a special pocket (12) at the waist or chest of the garment body in the form of a replaceable module.

8. The anti-fall head protection outdoor clothing and its manufacturing method according to any one of claims 1-7, characterized in that, The manufacturing process includes the following steps: S1: Preparation of composite protective structure: Based on the 3D scanning data of the key protective areas of the human body, the impact-resistant protective sheet (4) is molded as a passive buffer layer; high-toughness elastic fabric is cut and heat-synthesized into airbags (5) for each sub-area, with reserved inflation ports; the airbags (5) are pre-fixed to the passive buffer layer or reinforcing lining according to the design layout, and high-strength sewing thread with predetermined parameters is used to perform constraint sewing along the fold line of the airbags (5); S2: Integrated sensor and control system: The components of the sensor network are packaged on a flexible circuit board; the electrical interfaces of the packaged sensor module, control unit and gas generator (6) are connected by flexible wires and fixed in a predetermined position on the inner lining of the garment. S3: Garment assembly and composite structure implantation: Cut and sew the outer functional fabric, the middle waterproof and breathable membrane and the inner comfort lining to form the basic components of the garment body; place the composite protective structure prepared in step S1 on the inner comfort lining of the torso (1), sleeves (2) and hood (3); connect and seal the sensor control system cable of step S2 to the airbag (5) pipeline of the composite protective structure; integrate the composite protective structure, sensor control system and inner comfort lining into an inner lining module through quilting or partial bonding process; S4: Assembly and Testing: Combine and sew the integrated inner lining module with the outer fabric with the middle waterproof and breathable membrane to form a complete garment component; install the zipper, adjustment mechanism and the flexible expandable cavity; conduct air tightness test, sensor calibration and simulated trigger test to ensure that the airbag (5) can be smoothly deployed from the high-strength sewing line constraint as designed and form an effective cushioning air cushion.

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