A protective headgear comprising an energy absorbing material

Abstract

The disclosure relates to a protective headgear comprising an energy absorbing material comprising at least one thermoplastic elastomer (TPE) and a blowing agent comprising expandable microspheres, wherein the at least one TPE is a styrenic thermoplastic elastomer (TPS), and wherein said energy absorbing material comprises from 4 wt% to 10 wt% of said blowing agent.

Description

[0001] A PROTECTIVE HEADGEAR COMPRISING AN ENERGY ABSORBING MATERIAL

[0002] Field of invention

[0003] The invention relates to a protective headgear comprising an energy absorbing material.

[0004] Technical Background

[0005] Many injuries occur daily to humans due to absorption of impact energy. Especially vulnerable are infants and small children since they have delicate craniums that are sensitive to external shock and pressure. Children’s heads are also more exposed to bumps and thorns since their body coordination is not fully developed and falls and other minor accidents may occur almost daily. Elderly persons may also suffer from fragile bones and tend to have a higher risk of bone fractures, which may lead to some individuals experiencing anxiety and inhibition, preventing them from living a normal and active life. Moreover, children and adults who suffer from osteoporosis, also called brittle bone disease, have even more fragile bones and may need a protective arrangement to protect the person's head and / or body from external shock.

[0006] A protective arrangement, such as protective headgear, may help an individual suffering from fragile bones or other types of ailments to live a somewhat normal life and hopefully ease the anxiety for both the individual and their family and friends.

[0007] When designing a protective headgear, the designer typically takes a plurality of design criteria into consideration. The protective headgear should often be non-bulky and as comfortable as possible to wear. Additionally, the protective headgear should be wear-resistant, energy-absorbing, and washable. It is desirable if all parts of the protective headgear washable since this may facilitate a hygienic product. Many existing energy absorbing materials used in, e.g., clothes and headgears, must be removed from the clothing before wash to prohibit the material to not lose its properties.

[0008] Moreover, it is often desirable that the protective headgear is made from non-toxic materials. However, many energy absorbing materials used to absorb external shocks in headgears, clothes, or other products, often comprise toxic compounds, e.g., phthalates, polyvinyl chloride (PVC), flame retardants such as short-chain chlorinated paraffins (SCCP), and pigment. Polyurethane (Pll) is commonly used in materials configured to be energyabsorbing. However, polyurethane is known to be carcinogenic, allergenic, and asthma-inducing, thus, both users and individuals working with producing products containing Pll are exposed to health hazards. Therefore, in some countries, workers exposed to Pll, and other toxic thermoplastics, are by law mandated to undergo regular medical examination.

[0009] Another criterion to consider is that the protective material within the headgear should be temperature-resistant and keep its intended properties during normal use.

[0010] Currently, available protective headgears are oftentimes bulky, which makes such headgear uncomfortable to wear and noticeable to others. When designing a protective headgear, it is often desirous to make the energy absorbing material as thin as possible. However, a thinner energy absorbing material may instead result in insufficient protection and some energy absorbing materials require a relatively large material thickness to provide good energy absorbing capabilities, e.g., Ethylene vinyl acetate (EVA Foam).

[0011] Further, the energy absorbing materials offered on the market are often troublesome to integrate into a headgear or any type of garment since the energy absorbing material may be too thick or too hard to be able to be integrated with the headgear by e.g., sewing, which leads to the need for arranging such protective material, within the headgear, in the form of loose plates, arranged between at least two fabric layers. Such an arrangement suffers from the disadvantage of unintentional displacement of the protective material within the headgear, which may lead to impaired function of the headgear. Another integration method is using some type of adhesive to attach the energy absorbing material to the headgear; however, the use of adhesives may shorten the product life and the headgear or garment may not last several washes.

[0012] Considering the above, there is a need for energy absorbing material for use in a protective headgear that provides a proper fit and stays in place such that the protection capabilities are not altered. It is further desirable to provide an energy absorbing material that is easily integrated into the headgear and contain no toxic materials. Additionally, there exist a need of a non-bulky energy absorbing material which is relatively thin, but still provides good energy absorbing capabilities.

[0013] Summary

[0014] It is an object of the invention to provide a protective item for the head of a user, wherein the item comprises an energy absorbing material which eliminates the drawbacks mentioned above.

[0015] To this end, the present invention provides a protective headgear comprising an energy absorbing material comprising at least one thermoplastic elastomer (TPE) and a blowing agent comprising expandable microspheres, wherein the at least one TPE is a styrenic thermoplastic elastomer (TPS), wherein the energy absorbing material comprises from 4 wt% to 10 wt% of the blowing agent.

[0016] It is to be noted that the at least one TPS may be based on the compounds styrene-ethylene / butylene-styrene (SEBS) or styrene-butadiene- styrene (SBS) block copolymer. In the SBS block copolymer, the styrene end blocks provide the thermoplastic properties to the material and the butadiene mid-blocks provide the material with elastomeric properties. The block copolymer SEBS is produced by hydrogenating SBS such that the C=C bonds are eliminated which generates ethylene and butylene mid-blocks. These styrenic block copolymers (SBC) have at least the advantages of being non-toxic, UV and ozone resistance, and weathering resistant. These advantages are ideal when producing a product that is intended to have a long service life.

[0017] The TPS may be Dryflex® from HEXPOL Group. However, it is to be understood that another commercially available TPS known to the skilled person may be used in the energy absorbing material.

[0018] The term “blowing agent” in the context of the present invention means microspheres comprising a thermoplastic shell encapsulating a gas which may expand 50-100 times their original volume when exposed to heat. The blowing agent may be added to the composition before or after the expansion of the microspheres. It may be advantageous to add the blowing agent to the composition after the microspheres have been expanded since such an agent may improve uniformity of the energy absorbing material. However, it is to be understood that another commercially available blowing agent or a blowing agent known to the skilled person may be used in the energy absorbing material composition.

[0019] Expandable microspheres have good resilient properties such that they may restore their size and form after being compressed. The present invention thus offers an advantage of providing an energy absorbing material having relatively low density and high resiliency. As will be explained in detail below, the energy-absorbing material according to the present invention may be formed into a thin element, thus dramatically decreasing bulkiness, while maintaining the energy absorbing properties. As mentioned above, the energy absorbing material comprises from 4 wt% to 10 wt% of the blowing agent, preferably from 4 wt% to 8 wt%, more preferably from 6 wt% to 8 wt% of the blowing agent.

[0020] An advantage of the protective headgear comprising the energy absorbing material according to the present invention is that the energy absorbing capabilities of the material are sufficient even at very low thicknesses. This makes the energy absorbing material of the present invention particularly well-suited for use in protective headgears as the headgear may be very thin while still being able to provide superior energy absorbing properties.

[0021] Various types of energy absorbing materials are used in protective clothing. However, it should be understood that the choice of energy absorbing material may vary depending on the type of protective clothing. This variation is due to significant differences in the fragility and importance of different body parts. For instance, while kneepads are designed to protect against impacts and abrasions during activities like gardening or construction work, they do not require the same level of impact absorption and distribution as needed for head protection.

[0022] As an example, protective headgear, such as cycling helmets, are specifically engineered to absorb high-impact forces and distribute them across the helmet to minimize injury to the skull and brain. In contrast, kneepads are designed to protect against lower-impact forces and abrasions, which are common when kneeling.

[0023] Additionally, comfort and weight are critical factors in protective gear design. Head protection must be lightweight and comfortable enough to be worn for extended periods without causing fatigue or discomfort. As an example, kneepads prioritize flexibility and cushioning for the knees, and does not require the same level of breathability or ergonomic design as a protective headgear. Furthermore, protective headgears are designed to be as lightweight as possible while still providing maximum protection. Excessive weight on the head can lead to neck strain and reduced mobility. Kneepads can afford to be heavier since they are supported by the legs and do not impact overall mobility as significantly.

[0024] The protective headgear of the present invention provides excellent energy absorbing capabilities, is lightweight, non-bulky, and comfortable.

[0025] The blowing agent may be Expancel microspheres. Preferably, the additive is Expancel 930 MB 120 from Nouryon. Expancel 930 MB 120 has a particle size of around 120 pm in its expanded form.

[0026] The energy absorbing material according to the present invention may have a shore value in the range from 28 shore 00 to 80 shore A, preferably from 28 shore 00 to 50 shore A, more preferably from 28 shore 00 to 30 shore A. Such a material offers the advantage of rebound resiliency, i.e., the ability of the material to regain its original form after deformation. It’s a general practice of measuring the hardness of different materials by shore hardness. Shore 00 and Shore A are two hardness scales conventionally used in the art and are partly overlapping.

[0027] The energy absorbing material having the shore 00 or the shore A value as defined above offers the advantage of having good energy absorbing properties such that the energy absorbing material may absorb kinetic energy caused by an impact. It is to be noted that energy absorbing materials intended to be used in e.g., protective clothing may be desired to have different shore 00 or shore A values depending on the sought protection of the clothing. Energy absorbing materials having a lower shore A value, such as a value in the range 1 to 40, or a value in the shore 00 scale, may be more applicable to use in protective clothing for children and work wear, and energy absorbing materials having a relatively greater shore A value may be more applicable to use in e.g., motorcycle body armor. The energy absorbing material according to the present invention may have a thickness in the range from 1 to 10 mm, preferably from 4 to 8 mm. The low thickness of the energy absorbing material is advantageous since it provides a non-bulky appearance. The non-bulky appearance is advantageous when e.g., the energy absorbing material is to be integrated into a protective garment, such as a protective headgear. Despite the low thickness, the energy absorbing properties of the energy absorbing material according to the present invention are still satisfactory. The thickness of the energy absorbing material may, if desired, vary along the extension of the material, such that portions having different thickness are provided. For instance, an upper part may be thinner than a lower part, or vice versa. Additional advantages relative to integrating the energy absorbing material in a protective headgear will be explained in detail below.

[0028] The energy absorbing material may have a melt flow rate in the range from 50 g / 10 min to 80 g / 10 min, preferably from 60 g / 10 min to 70 g / 10 min. It is to be noted that the melt flow rate may be different from the above specified intervals.

[0029] The energy absorbing material may have a tear strength in the range from 5 MPa to 7 MPa, preferably 6 MPa.

[0030] The energy absorbing material according to the present invention may have stress at 100 % in the range from 0.5 to 0.7, preferably 0.6.

[0031] The energy absorbing material according to the present invention may be formed by compression molding or injection molding. An advantage of using compression molding when producing the energy absorbing material is an improved expansion control, since the composition does not tend to expand noticeably after the compression molding process is completed. This may be important in a product where it is of high significancy that the thickness of the energy absorbing material is within the acceptable range to provide reliable energy absorbing properties. However, this tendency for post- molding expansion has been recognized when the energy absorbing material is formed by injection molding, which is the most common process used when molding thermoplastic elastomers. Thus, the compression molding process may allow for a more reliable and controllable forming process, however, it is to be understood that the energy absorbing material may be formed by injection molding.

[0032] The barrel temperature during the injection molding may be in the range from 160°C to 210°C.

[0033] The mold temperature during the injection molding may be in the range from 20°C to 80°C.

[0034] The mold temperature during compression molding may be 160°C to 210°C.

[0035] The energy absorbing material may be washable in temperatures from 30°C to 60°C, without losing its properties.

[0036] The protective headgear according to the present invention may comprise at least one fabric layer, and the energy absorbing material is in such an embodiment arranged adjacent to the at least one fabric layer.

[0037] The protective headgear may be any type of headgear configured to protect the head from external shocks. The protective headgear may for example be a beanie, a helmet, a hardhat, or a cap. It is to be understood that the energy absorbing material disclosed herein, is also applicable to be used in a protective garment other than a protective headgear, such as a jacket, a sweater, a pair of trousers, shoes, underwear or socks.

[0038] The term “adjacent to” in the context of the present invention means that the energy absorbing material is arranged in contact with the fabric layer. The energy absorbing material being arranged in contact with the at least one fabric layer may be arranged to be attached to the at least one fabric layer by being e.g., sewn, glued, or connected using Velcro. In an embodiment where the protective headgear comprises more than one fabric layer, the energy absorbing material may be arranged adjacent to one or more of the fabric layers. The multiple fabric layers may be arranged on one side of the energy absorbing material, such that at least one fabric layer is an intermediate fabric layer positioned adjacent to another fabric layer and the energy absorbing layer. The intermediate layer may be an isolating fabric layer to make the protective headgear less thermally conductive, such that the headgear provides comfort at sub-zero temperatures.

[0039] When the protective headgear comprises more than one fabric layer, e.g., two fabric layers, the fabric layers may be arranged on a respective side of the energy absorbing material, such that the energy absorbing layer is arranged between the two fabric layers and may be at least partially surrounded by fabric. Preferably, the energy absorbing material is fully surrounded by the fabric layers. Such an embodiment offers the advantage of improved perception of the headgear by the skin of the user, and also appealing aesthetical appearance.

[0040] The term “between” in the context of the present invention means that the energy absorbing material is arranged within the protective headgear. In such an embodiment, the first fabric layer may be arranged to face the body of the user, and the second fabric layer may be arranged to face the ambient, wherein the energy absorbing material may be arranged between the two fabric layers. The energy absorbing material may be arranged in an existing pocket of the protective headgear. Alternatively, the energy absorbing material may be placed between the two fabric layers before the protective headgear is finalized in the manufacturing process.

[0041] It is to be noted that a protective headgear which comprises more than one fabric layer, may comprise fabric layers of different materials. The energy absorbing material may be connected to the protective headgear by being sewn to at least one fabric layer, or by means of e.g., Velcro, glue, tape, snap fasteners, arranged within a pocket of the headgear or arranged between two, or more, fabric layers.

[0042] If the energy absorbing material is to be arranged in an protective garment, not being a protective headgear, the energy absorbing material may be arranged within, or on, a protective garment at a specific location corresponding to a portion of the body where additional protection is needed, e.g., the area around the knees, the rump, or the hips, in a pair of trousers, the area around the elbows, spine, chest, or shoulders, in a shirt or a jacket, the area around the wrist, the palm, or the knuckles, in a pair of gloves.

[0043] As described above, the energy absorbing layer may have a thickness in the range from 1 to 10 mm. The relatively low thickness of the energy absorbing material, in conjunction with the relatively low shore 00 or shore A value provides for a material which can be sewn into. This is advantageous since it provides for a material which may easily be integrated to any protective garment, especially a protective headgear.

[0044] Another advantage of having a material which can be sewn into is that separate elements of the energy absorbing material may be connected to each other to form a larger piece of the energy absorbing material, which in turn may provide a more flexible layer of the energy absorbing material compared to one large single blank of the energy absorbing material. Further, fitting properties of a piece of the energy absorbing material comprising separate elements is greatly improved.

[0045] Another advantage, related to sewing into the energy absorbing material, is that the usage of potentially toxic adhesives may be avoided.

[0046] By sewing the energy absorbing material to at least one fabric layer of the protective headgear, the energy absorbing material is held in its intended position during wearing and washing, and thus, the protective properties of the headgear are not altered during repeated use.

[0047] If desired, the protective headgear may be designed such that the energy absorbing material may be easily detached from the protective headgear by e.g., having the energy absorbing material arranged within a pocket of the protective headgear or by the use of Velcro. Such an embodiment offers the advantage of providing the possibility to replace the energy absorbing material in a case where the energy absorbing material is worn out faster than the protective headgear, or vice versa. Another advantage of having detachable energy absorbing material is a possibility to remove the energy absorbing material during washing of the headgear. This may be of a particular importance when the protective headgear is intended to be worn by a child and thus requires frequent washing.

[0048] For providing additional protection, the protective headgear of the present invention may comprise more than one energy absorbing material layer such that a plurality of energy absorbing material layers is placed on top of each other providing a thicker energy absorbing layer within the protective headgear. However, this is not necessary for providing efficient energy absorbing properties.

[0049] It is to be understood that the energy absorbing material may be arranged within any protective garment to provide additional protection to several parts of the body, e.g., in a pair of trousers, it may be desired to have energy absorbing material arranged at a location around both knees and on each hip of the user.

[0050] The protective headgear may be a beanie, or any other type of headgear, configured to protect the head from external shocks, e.g., a helmet or a cap. In one embodiment, the beanie may comprise one fabric layer having an inner and an outer surface, wherein the outer surface faces the ambient and the inner surface faces the head of the user. In such an embodiment, the energy absorbing material may preferably be arranged on the outer surface of the fabric layer to provide a more comfortable usage.

[0051] In another embodiment, the beanie may comprise at least two fabric layers configured to form an outer and inner layer of the beanie, wherein the outer layer faces the ambient, and the inner layer faces the head of the user.

[0052] The beanie comprises at least one layer of the energy absorbing material. Preferably, the at least one layer of energy absorbing material is configured to, at least partially, form a middle layer.

[0053] By the term “at least partially” it is to be understood that the energy absorbing material may not be present in all areas of the beanie. Put differently, the energy absorbing material may form a middle layer in a specific area of the beanie, e.g., at a lower circumferential portion of the beanie, providing protection to the forehead, the sides, and / or the back of the head.

[0054] An advantage of having the energy absorbing material positioned between at least two fabric layers is that it provides for a more comfortable and aesthetic product. However, it is to be noted that the beanie may comprise only one fabric layer, wherein the energy absorbing material is attached to the one fabric layer such that the energy absorbing material is visible.

[0055] The at least two fabric layers may be a textile with high durability, such as jersey fabric. An advantage of having jersey fabric as the main textile of the protective headgear is that jersey fabric has good breathability and moisture wicking properties. However, it is to be understood that any other textile, suitable to be used in a headgear may be used, e.g., fleece, cotton, wool, polyester fiber, or any commonly known fabric used in headgears.

[0056] It should be noted that the protective headgear, e.g., a beanie, may merely consist of the energy absorbing material. The energy absorbing material, comprised in e.g., the beanie, may comprise at least two elements configured to be connected to the protective headgear. In particular, the energy absorbing material may comprise a first, and a second element arranged to be connected to at least one fabric layer of the protective headgear and arranged one after the other along a longitudinal direction, such that the first, and the second elements form a loop of energy absorbing material. The loop may have a first longitudinal edge portion. The loop may have a circular shape, suitable for surrounding the head of the user.

[0057] The first and second elements may each comprise two transversally extending sides, wherein the transversally extending sides of the first element are to be arranged nearby the transversally extending sides of the second element. Put differently, the transversally extending sides of the first element may be neighboring the transversally extending sides of the second element.

[0058] The term “neighboring” in the context of the present invention means that the respective elements may, by their respective transversally extending sides, be arranged one after the other in the longitudinal direction such that there is a small gap between the respective elements. The gap may be in the range of 1 to 100 mm. It is to be noted that the gap between two neighboring elements allows the beanie to stretch such that the beanie may be comfortable to wear.

[0059] Alternatively, the respective element may abut with a neighboring element at a respective transversally extending side thereof, thus forming a continuous loop. The continuous loop may have a circular shape, suitable for surrounding the head of the user.

[0060] It is to be noted that the energy absorbing material may comprise more than two elements configured to be connected to at least one fabric layer of the protective headgear and arranged one after the other along a longitudinal direction. In particular, the energy absorbing material may comprise a first, a second, and a third element arranged to be connected to at least one fabric layer of the protective headgear and arranged one after the other along a longitudinal direction, such that the first, the second, and the third elements form a loop of energy absorbing material. The loop may have a first longitudinal edge portion.

[0061] It is to be noted that the energy absorbing material may comprise only one element.

[0062] The width of the respective first, second and third element may define the size of the protective headgear, particularly if the protective headgear is a beanie or a cap. The beanie may have the sizes of 48-51 , 51-55, 55-58 or 58- 62, which corresponds to the circumferential measurement of head of the user. However, it is to be understood that the beanie may have another size than presented above.

[0063] The elements of the energy absorbing material may have any suitable shape, depending on the protective headgear in which the elements are intended to be used. The elements of the energy absorbing material may be rectangular, circular, elliptic, triangular or the like.

[0064] The respective element of the energy absorbing material may have a substantially rectangular shape. The term “substantially rectangular” in the context of the present invention means that the respective element has four main sides, wherein the respective main side extends longitudinally or transversally substantially parallel to each other, and wherein a respective side may have a curvature and / or some type of irregularities, such as protrusions or recesses. This may also be true if the energy absorbing material has another shape than rectangular.

[0065] The respective element of the energy absorbing material may have a first width in the range of 150 to 350 mm. However, it is to be understood that the width of the respective element may have another value, different from the width range described above. The element may have a first width at a lower portion and a second width at an upper portion, such that the element is tapered in the transversal direction. The first width may be greater than the second width, or the first width may be less than the second width of the respective element. It is to be understood that the first and / or second width of a respective element may be the same or different relative to a respective first or second width of another element.

[0066] The respective element of the energy absorbing material may have a first height in the range of 100 to 300 mm. However, it is to be understood that the height of the respective element may have another value, different from the height range described above. The element may have a first height at a middle portion and a second height at an end portion, such that the element is tapered in the longitudinal direction towards the respective transversally extending side. The first height may be greater than the second height, or the first height may be less than the second height of the respective element. It is to be understood that the first and / or second height of a respective element may be the same or different relative to a respective first or second height of another element.

[0067] As beforementioned, the energy absorbing material according to the present invention may have a thickness in the range from 1 to 10 mm, preferably from 4 to 8 mm. The respective element of the energy absorbing material may have varying thicknesses along the extension of the element. The element may have thickness along the transversally extending sides being greater or less than the thickness along the longitudinally extending sides. The element may have a thicker middle portion, wherein the thickness decreases towards the sides of the element, or vice versa. In the cases where the protective headgear is a beanie, it may be advantageous to have a relatively thin outer rim of the respective element to provide a more comfortable fit of the beanie and better facilitate the separate elements to be connected to the protective headgear by sewing. However, by still having a middle portion, enclosed by the outer rim, having a relatively thicker material thickness, sufficient energy absorbing properties are still provided. The outer rim may for example have a thickness in the range of 1 to 3 mm, and the middle portion may have a thickness in the range of 4 to 8 mm.

[0068] At least one of the respective elements may comprise a recess having a recess height extending in a transverse direction being substantially perpendicular to the longitudinal direction, and a recess width extending in the longitudinal direction, the recess being arranged adjacent to the first longitudinal edge portion of the energy absorbing material. Preferably, both the first and the second elements comprise a recess.

[0069] The recess may have a recess height in the range of 5 to 30 mm. The recess may have a recess width in the range of 10 to 40 mm. The recess of the first and second element may be positioned at a respective corner portion. The recess provides the protective beanie with an improved comfort for the user since it allows the fabric layers of the beanie to stretch. The beanie may be placed upon the head of the user such that the respective recess is positioned at an area around the user’s ears, e.g., above the ears or at the temples. However, the recess may be placed upon the head of the user such that the respective recess is positioned differently than described above.

[0070] The energy absorbing material may be arranged with multiple perforations to accommodate air vents. The perforations may have a diameter in the range of 0.5 to 3 mm. Indeed, the perforations may have another diameter if suitable.

[0071] The energy absorbing material may be manufactured by a method comprising the steps of: a) mixing TPS, preferably in the form of granulates, and the blowing agent comprising expandable microspheres to form a molding mixture, b) forming the molding mixture into the energy absorbing material by compression molding. The compression molding may be performed in a mold which have a mold temperature in the range of 160 °C to 210°C, and wherein the molding mixture, when formed, may be exposed to a compressive pressure generally used in the process of compression molding.

[0072] As previously mentioned, an advantage of using compression molding when producing the energy absorbing material, is that an improved expansion control, since the composition does not tend to expand noticeably after the compression molding process is completed.

[0073] This advantage may be important when producing a product where it is of high significance that the thickness of the energy absorbing material is within an acceptable range to provide reliable energy absorbing properties. However, this tendency for post-molding expansion has been recognized when the energy absorbing material is formed by injection molding, which is the most common process used when molding thermoplastic elastomers. Thus, the compression molding process may allow for a more reliable and controllable forming process. However, it is to be understood that the energy absorbing material may be formed by injection molding.

[0074] Brief description of the drawings

[0075] The invention will by way of example be described in more detail with reference to the appended schematic drawings, which shows a presently preferred embodiment of the invention.

[0076] Figure 1a-b discloses a schematic and a cross-sectional view of a beanie comprising two respective elements of an energy absorbing material.

[0077] Figure 2 disclose a schematic view of the element shown in the figures 1a-b.

[0078] Figure 3 disclose a cross section view of the element shown in the figures 1a-b and 2. Figure 4 discloses a schematic view of an energy absorbing material comprising a first, a second, and a third element arranged one after the other along a longitudinal direction, such that the first, the second, and the third elements form a loop of elements.

[0079] Figure 5a-d discloses a schematic view of an alternative element of the energy absorbing material.

[0080] Figure 6a-b discloses a schematic view of another alternative embodiment of the energy absorbing material which is arranged within a cap.

[0081] Detailed description of embodiments

[0082] With reference to Figs.1a-b, a protective headgearl , formed as a beanie 10, comprises a first and a second element 20 of the energy absorbing material 2 is shown. The beanie 10 is configured to protect the head of the user from external shocks and is to be worn on the head as a regular beanie. The first and the second element 20 are connected to at least one fabric layer 11 of the protective headgear 1 and arranged one after the other along the longitudinal direction L, such that the first and the second element 20 form a loop. The loop has a first longitudinal edge portion 21 . The loop has a circular shape, suitable for surrounding the head of the user, as shown in Fig.1a.

[0083] The first and second element 20 each comprises two transversally extending sides 23, wherein the respective transversally extending sides 23 of the first and second element 20 are arranged to be neighboring another respective transversally extending side 23 of another element 20. Put differently, the transversally extending sides 23 of the first element 20 are neighboring respective transversally extending side 23 of the second element 20. The term “neighboring” refers to that the respective elements 20 may, by their respective transversally extending sides 23, be arranged one after the other in the longitudinal direction L such that there is a small gap 40 between the respective elements. The width of the gap 40 may be in the range of 1 to 100 mm. The width of the gap 40 may vary along the extension of the gap, as shown in Fig.1a.

[0084] In another embodiment, the respective element 20 may abut with a neighboring element 20 at a respective transversally extending side 23 thereof, thus forming a closed loop. The closed loop may have a circular shape, suitable for surrounding the head of the user.

[0085] As shown in Fig. 1 b, the protective beanie 10 further comprises two fabric layers 11a, 11 b arranged on a respective side of the energy absorbing material 2 such that the energy absorbing layer 2 is arranged between the two fabric layers 11a, 11b and such that the energy absorbing material 2 is arranged adjacent to both fabric layers 11 as an intermediate layer and provides protection to the forehead, parts of the sides, and the back of the user’s head. The term “adjacent to” in the context of the present invention means that the energy absorbing material 2 is arranged in contact with the fabric layer 11. The energy absorbing material 2 being arranged in contact with the at least one fabric layer 11 may be arranged to be attached to the at least one fabric layer 11 by being e.g., sewn, glued, or connected using Velcro.

[0086] As shown in Fig. 1 b, the first and second element 20 are arranged between the two fabric layers 11 and is fully surrounded by fabric. The term “between” in the context of the present invention means that the energy absorbing material 2 is arranged within the protective headgear 1. The first fabric layer 11a is arranged to face the body of the user, and the second fabric layer 11b is arranged to face the ambient, wherein the energy absorbing material 2 is arranged between the two fabric layers 11a, 11 b. In another embodiment, not shown in any of the figures, the energy absorbing material 2 may be arranged within an existing pocket of the protective headgear 1 . The embodiment shown in Figs.1a-b, has been manufactured by placing the energy absorbing material 2 between the two fabric layers 11 before the protective headgear 1 is finalized in the manufacturing process. In another embodiment, not shown, the beanie 10 may comprise only one fabric layer 11 having an inner and an outer surface, wherein the outer surface faces the ambient and the inner surface faces the head of the user. In such an embodiment, the energy absorbing material 2 may preferably be arranged on the outer surface of the fabric layer 11 to provide a more comfortable usage.

[0087] The energy absorbing material 2, as shown in Figs. 1a-b, is attached to the protective headgear 1 by being sewn to at least one of the fabric layers 11 . The energy absorbing layer may be sewn to at least one fabric layer 11 such that there extends a seam 29 along the first longitudinal edge portion 21 of the respective element 20. As shown in Figs.1a-b, the first longitudinal edge portion 21 of the element 20 is placed adjacent to a longitudinal edge portion 12 of the beanie 10. In another embodiment, the energy absorbing material 2 may be sewn on to the beanie 10, at least partially, along the outer rim of the respective element 20. In another embodiment, the energy absorbing material 2 may be attached to the protective headgear 1 by means of e.g., Velcro, glue, tape, snap fasteners, or arranged within a pocket of the protective headgear 1.

[0088] Each respective element 20 of the energy absorbing material layer 2 may have a thickness in the range from 1 to 10 mm. The relatively low thickness of the energy absorbing layer 2, in conjunction with the relatively low shore 00 or shore A value, provide a material which can be sewn into. This is advantageous since it provides for a material which may easily be integrated to the protective headgear 1 and wherein several separate elements 20 of the energy absorbing material 2 may be connected by being sewn together. By sewing the energy absorbing material 2 to at least one fabric layer 11 of the protective headgear 1 , the energy absorbing layer 2 is held in its intended position during use and wash, and thus, the protective properties of the headgear 1 are not altered.

[0089] The two fabric layers 11 may be made of a textile with high durability, such as jersey fabric. However, it is to be understood that any other textile, suitable to be used in e.g., a beanie, may be used, e.g., fleece, cotton, wool, polyester fiber, or any type of fabric commonly used in headgears. In one embodiment, not shown in any of the figures, the beanie may merely consist of the energy absorbing material.

[0090] The energy absorbing material 2 shown in Figs. 1-5 comprises at least one thermoplastic elastomer (TPE) and a blowing agent comprising expandable microspheres. The at least one TPE is a TPS. The energy absorbing material 2 comprises from 4 wt% to 10 wt% of the blowing agent, and wherein said energy absorbing material 2 has a shore value in the range from 28 shore 00 to 80 shore A, preferably from 28 shore 00 to 50 shore A, more preferably from 28 shore 00 to 30 shore A.

[0091] With reference to Fig. 2, a first element 20 of the energy absorbing material 2 is shown. The first element, shown in Figs. 1a-b, 2, and 3, has a substantially rectangular shape. The term “substantially rectangular” in the context of the present invention means that the respective element has four main sides 22, 23, wherein the respective main side 22, 23 extends longitudinally or transversally, and wherein a respective side 22, 23 may have a curvature and / or some type of irregularities, such as protrusions or recesses. The elements 20 of the energy absorbing material 2 may have a shape different from the shape shown in Figs. 1-3. It is to be understood that the energy absorbing material 2 may have any suitable shape, depending on the protective headgear 1 . The elements 20 of the energy absorbing material 2 may be rectangular, circular, triangular, elliptic or the like.

[0092] The first width W1 of the respective first and second element 20 may together define the size of the protective headgear, particularly if the protective headgear is a beanie. The beanie may have the sizes of 48-51 , 51- 55, 55-58 or 58-62, which corresponds to the circumferential measurement of the head of the user. However, it is to be understood that the beanie may have another size than presented above.

[0093] As shown in Fig. 2, the element 20 of the energy absorbing material 2 has a first width W1 . The first width W1 may be in the range of 150 to 350 mm. However, it is to be understood that the first width W1 of the respective element may have another value, different from the width range described above. The respective element 20 has a first width W1 at a lower portion 24 and a second width W2 at an upper portion 25, such that the element 20 is tapered in the transversal direction T. The first width W1 is greater than the second width W2. It is to be understood that the first and / or second width W1 , W2 of a respective element 20 may be the same or different relative to a respective first or second width W1 , W2 of another element 20.

[0094] The two elements 20 of the energy absorbing material 2 may have a first height H1 in the range of 100 to 300 mm. However, it is to be understood that the height H1 of the respective element 20 may have another value, different from the height range described above. The element 20 has a first height H1 at a middle portion 26 and a second height H2 at an end portion arranged in the proximity of the transversally extending sides 23, such that the element 20 is tapered in the longitudinal direction L towards the transversally extending sides 23. The first height H1 is greater than the second height H2. It is to be understood that the first and / or second height H1 , H2 of the respective element 20 may be the same or different relative to the respective first or second height H1 , H2 of another element 20.

[0095] As shown in Fig. 2, the element 20 comprises two respective recesses 27 arranged at a lower portion 24 of the element 20 such that it interrupts the first longitudinal edge portion 21 . The respective recess 27 has a recess height extending in the transverse direction T being substantially perpendicular to the longitudinal direction L, and the width of the recesses 27 extends in the longitudinal direction L. In another embodiment, the recesses 27 may be arranged adjacent to the first longitudinal edge portion 21 of the energy absorbing material 2. It is also to be noted that the respective element may comprise no recess, or only comprise one recess 27 adjacent to the first longitudinal edge portion 21 of the energy absorbing material 2, or more than two recesses.

[0096] The recesses 27, as shown in Figs.1a-b, 2, are arranged in a respective corner portion of the element 20 which is arranged in the lower portion 24 at a respective connecting point of the lower longitudinally extending side 22 and the respective transversally extending sides 23.

[0097] The recess 27 provides the protective beanie 10, as shown in Fig.1 , with an improved comfort for the user since it allows the fabric layers 11 of the beanie to stretch in the area of the recess 27. The beanie 10 may be placed upon the head of the user such that the respective recess 27 is positioned at an area around the user’s ears, e.g., above the ears or at the temples, as shown in Fig. 1a. However, the beanie 10 may be placed upon the head of the user such that the respective recesses 27 are positioned differently than described above.

[0098] The recess height, may be in the range of 5 to 30 mm. The recess may have a recess width in the range of 10 to 40 mm.

[0099] As shown in Figs. 1-3, the energy absorbing material 2 is arranged with multiple perforations 28 to accommodate air vents. The perforations 28 may have a diameter in the range of 0,5 to 3 mm. Indeed, the perforations 28 may have another diameter if suitable.

[0100] With reference to Fig. 3, and also shown in Fig. 1 b, each respective element 20 of the protective headgear 1 has varying thicknesses along the element’s extension. The element 20 may have one thickness along the transversally extending sides 23 being greater or less than the thickness along the longitudinally extending sides 22. The thickness along the transversally and longitudinally extending sides 22, 23 may also be the same. As shown in Fig. 3, the element 20 has first thickness T1 forming a thicker middle portion 26, wherein the thickness decreases towards the sides 22, 23 of the element 20 such that there is formed a second thickness T2. It is to be noted that the energy absorbing material 2 according to the present invention may have a thickness varying in the range from 1 to 10 mm, preferably 4 to 8 mm.

[0101] In the cases where the protective headgear is a beanie 10, as shown in Fig 1a-b, it may be advantageous to have a relatively thin outer rim of the respective element 20 to provide a more comfortable fit of the beanie 10 and to better facilitate the separate elements 20 to be connected to the fabric layer 11 of the beanie 10 by sewing. However, by still having a middle portion 26, enclosed by the outer rim, having a relatively thicker material thickness, sufficient energy absorbing properties are still provided. The second thickness T2 of the outer rim may be in the range of 1 to 3 mm, and wherein first thickness T 1 the middle portion 26 may be in the in the range of 4 to 8 mm.

[0102] With reference to Fig. 4, the energy absorbing material 2 comprises a first, a second and a third element 20 configured to be connected to the protective headgear 1 . The first, second and third element 20 is arranged one after the other in the longitudinal direction L such that a loop of elements 20 is formed. The loop may form a first longitudinal edge portion 21 .

[0103] The first, second and third element 20, as shown in Fig. 4, are arranged such that there exists a gap 40 between the respective element 20 and a neighboring respective transversally extending side 23 of another element 20. The gap 40 may be in the range of 1 to 100 mm. In another embodiment, the respective element 20 may abut with a neighboring element 20 at a respective transversally extending side 23 thereof. The elements 20, shown in Fig. 4, may be attached to the protective headgear 1 by being sewn along the longitudinal side 22, or at least along one of the transverse sides 23. The element 20 may be attached to the protective headgear 1 by being sewn along each respective side 22, 23.

[0104] With reference to Figs. 5a-d, the energy absorbing material 2 is formed into an alternative element 20' and arranged in a beanie 10, as shown in Fig. 5a and 5c. One respective element 20' of the energy absorbing material 2 is sewn together with at least one other respective element 20' along a transversally extending side 23' thereof, as shown in Figs. 5b and 5d. In Fig. 5a, a beanie 10 with five respective elements 20' is shown, wherein the elements 20' are sewn together three by three and two by two, forming a first and a second sets of elements 20', as shown in Fig. 5b.

[0105] Moreover, in Fig. 5c, a beanie 10 with six respective elements 20' is shown, wherein the elements 20' are sewn together three by three, and thereby also forming a first and a second sets of elements 20', as shown in Fig. 5d.

[0106] The first and second set are arranged within the beanie 10 to form a continuous loop of elements 20' such that the head of the user is substantially protected.

[0107] As shown in Figs. 5a-d, an element 20' does not comprise a recess 27' if the element 20' is arranged as an intermediate element 20' relative two respective elements 20'. Each respective element 20' being an outer element comprises a recess 27' arranged at a free transversally extending side 23' being opposite the transversally extending side 23' being connected to an intermediate element 20'.

[0108] Due to the relatively thin material thickness of the energy absorbing material 2, it is possible to sew together the respective elements 20'. With reference to Fig. 6a-b, a protective headgear 1 formed as a cap 110 is shown. The cap 110 comprises an alternative embodiment of the element. The element 300 is concavely shaped and is configured to extend around the user’s head at least partially.

[0109] As shown in Fig. 6a, the element 300 comprises multiple perforations 380 to accommodate air vents. The perforations 380 may have a diameter in the range of 0,5 to 3 mm. Indeed, the perforations 380 may have another diameter if suitable.

[0110] The element 300, as shown in Figs. 6a-b, comprises a recess 370 extending from an upper portion 310 to a first longitudinal edge portion 320 of the element 300. The recess may have different widths along its extension, as seen in Figs. 6a-b. The recess may have a wider portion in proximity of the first longitudinal edge portion 320. The wider portion may be arranged such that it is located in the back of the cap 110.

[0111] Examples

[0112] The energy absorbing material of the present invention, with some differentiating material compositions, together with some known energy absorbing materials available on the market, have been tested according to the standardized test method EN 812 and EN 1621-1 , as shown in Table 1 and Table 2, to determine the force that is not absorbed by the energy absorbing material, i.e. , the force to which the user is subjected to. The terms “Test 1” and “Test 2”, as described in Table 1 and Table 2, refer to two different TPS materials from Hexpol named Dryflex®. The difference between the two specified materials may be the shore value. Table 1 - Measured force during the test performed according to EN 812

[0113] During the test, it was found that the energy absorbing layer of the present invention, comprising Test 1 or Test 2, had better energy absorbing capabilities, even at lower material thicknesses, than the compared product from the brand NG Baby, owned by Pro Support Scandinavia AB, as shown in Table 1. This entails that the present invention provides better protection, at lower material thicknesses, which provides a safer and less bulky product which in turn provides a product which is aesthetically appealing and increases usability. Table 2 - Measured force during the test performed according to EN

[0114] 1621-1

[0115] During the test, performed according to the standardized method EN 1621 -1 , it was found that the energy absorbing material according to the present invention had better energy absorbing capabilities than all compared materials, even at lower thicknesses. The results, as shown in Table 2, may be concluded in accordance with the conclusion in regard to the results as shown in Table 1 . Even though it is preferred that the protective headgear is designed in accordance with the disclosure in the detailed disclosure of preferred embodiments and the appended drawings, it should be noted that a specific preferred embodiment of a specific component does not necessarily have to be combined with a specific embodiment of another component. Thus, advantages associated with a specific embodiment, including one or more features of a specific component may be accomplished even though the other component(s) is / are designed in accordance with the more general disclosure under the summary of the invention rather than being defined in accordance with the specific embodiment disclosed in the detailed description.

[0116] It is contemplated that there are numerous modifications of the embodiments described herein, which are still within the scope of the invention as defined by the appended claims.

[0117] The protective headgear may for instance comprise energy absorbing material on both sides if a fabric layer, or the protective headgear mat comprise additional energy absorbing material different from the energy absorbing material of the present invention.

[0118] Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.

Claims

CLAIMS1 . A protective headgear comprising an energy absorbing material, the energy absorbing material comprising at least one thermoplastic elastomer (TPE) and a blowing agent comprising expandable microspheres, wherein the at least one TPE is a styrenic thermoplastic elastomer (TPS), wherein said energy absorbing material comprises from 4 wt% to 10 wt% of said blowing agent.

2. The protective headgear according to claim 1 , wherein the expandable microspheres comprise a thermoplastic shell encapsulating a gas.

3. The protective headgear according to any one of the preceding claims, wherein said energy absorbing material has a thickness in the range from 1 mm to 10 mm.

4. The protective headgear according to any one of the preceding claims, wherein said energy absorbing material has a shore value in the range from 28 shore 00 to 80 shore A, preferably from 28 shore 00 to 50 shore A, more preferably from 28 shore 00 to 30 shore A.

5. The protective headgear according to any one of the preceding claims, said energy absorbing material having a tear strength in the range from 5 MPa to 7 MPa, preferably 6 MPa.

6. The protective headgear according to any one of the preceding claims, wherein said energy absorbing material is formed by compression molding or injection molding.

7. The protective headgear according to any one of the preceding claims, wherein said protective headgear comprises at least one fabric layer, and wherein said energy absorbing material is arranged adjacent to said at least one fabric layer.

8. The protective headgear according to any of the preceding claims, wherein said protective headgear comprises two fabric layers, wherein said energy absorbing material is arranged between said two fabric layers.

9. The protective headgear according to any one of the preceding claims, wherein said energy absorbing material is attached to said at least one fabric layer.

10. The protective headgear according to any one of the preceding claims, wherein said energy absorbing material comprises at least two elements configured to be to be neighboring each other.11 . The protective headgear according to any one of the preceding claims, wherein said at least two elements are arranged to be neighboring each other along a longitudinal direction, such that said first and said second elements form a loop, said loop having a first longitudinal edge portion.

12. The protective headgear according to any one of the preceding claims, wherein at least one of said two elements comprise a recess extending in a transverse direction being substantially perpendicular to said longitudinal direction, said recess being arranged adjacent to said first longitudinal edge portion.

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