COMPRESSION FORCE ADAPTIVE HEADGEAR AND METHOD PRIOR APPLICATION This application claims the benefit of U.S. Provisional Patent Application No. 63,426,776, filed November 20, 2022, which is incorporated herein by reference.

Abstract

A body-worn device (40) for accommodating compressive forces on a wearer's head. The device can include a rigid brace (42) that spans the head (10) substantially in the direction of a hat brim. The brace can include a pair of extension arms (44a, 44b) that extend laterally and rearward away from the temples. Rear tensioning members (51, 52) position the free ends (45b, 46b) of the arms under a lateral inward compressive force that is resisted by the stiffness of the brace, avoiding compression in the temple region of the head and thereby enhancing comfort.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION The present invention relates to body worn supports, and more particularly to load bearing headgear. [Background technology]

[0002] Many types of headgear have been developed to accommodate the forces exerted on the head. For example, helmets have been used for centuries to protect the wearer's head from injuries caused by impacts from large and small foreign objects.

[0003] Referring now to the drawings, FIG. 1 shows that the human head 16 can be substantially bisected by three mutually orthogonal planes. The sagittal plane SP bisects the head vertically into left and right lateral halves. The coronal plane CP substantially bisects the head vertically into anterior and posterior portions. The transverse plane TP substantially bisects the head horizontally into superior and inferior portions. The word substantially is used because the head is not symmetrical across the coronal or transverse planes. As used herein, the sagittal, coronal, and transverse planes intersect the center of gravity or volume of the head. These planes help define the function of the headgear.

[0004] 2 and 3 show that a typical prior art headgear 20 can be attached to a user's head 10. The headgear can include a flexible or semi-rigid headband 22 that encircles the head substantially in the transverse plane TP, along with a flexible or semi-rigid vertical retention band 23 that extends across the top of the head substantially in or parallel to the coronal plane CP. The headgear can typically use a flexible headband to allow fine adjustment to the user's head for improved fit and comfort. The headgear can be used to support an attachment 21, such as a headlamp, that protrudes forward from the front of the headgear. This type of attachment can be cantilevered such that the weight W of the attachment under the influence of gravity creates a moment of force at the attachment point to the headband. This moment of force is often strong enough to cause a downward deflection of the attachment from its original position 24. Thus, the rigid interface structure 25 between the attachment and the headband can be driven to pitch downwards against a lower contact point 26 with the forehead causing discomfort.

[0005] As shown primarily in Figure 3, downward deflection of attachment 21 tends to cause top edge 27 of headband 22 to peel forward 28 away from user's head 10, often creating a gap 29 between the head and the top edge. Greater tension on the top end of the headband can cause uncomfortable inward pinching 19a, 19b of the headband against the temples. During stress-related headaches, constant pressure on the temples can often result in greater discomfort.

[0006] U.S. Patent Application No. 17737881 to Malcolm et al. describes a headgear for connecting a head to a body-worn device designed to support the head and neck from excessive fatigue during repetitive, prolonged activities, such as assembly line worker tasks. The device uses an adjustable cable to connect the headgear to a variable stiffness semi-rigid support member secured to the user's back. Tension on the cable can cause the headband to flex inward, creating uncomfortable pressure points against the skull.

[0007] Composite materials such as carbon fiber reinforced polymers have long been used to make structural elements because these materials are lightweight and have high stiffness / strength against bending moments along the elliptical fiber orientation. Malcolm, U.S. Patent No. 10,315,745, describes oriented layers of fiber to tailor the longitudinal and rotational stiffness in different regions of a composite member.

[0008] Therefore, there is a need for an apparatus that addresses one or more of the above-identified shortcomings. Summary of the Invention [Problem to be solved by the invention]

[0009] SUMMARY OF THE INVENTION It is a primary and secondary object of the present invention to provide an improved compression adaptive headgear system. [Means for solving the problem]

[0010] These and other objectives may be achieved by a rigid, arcuate front brace that includes cantilevered support arms that resist lateral compressive forces.

[0011] In some embodiments, a combination headgear and a substantially stationary support connected to the headgear by a spanning cable is provided.

[0012] In some embodiments, there is provided a device worn on a user's head, the device comprising: a rigid, arcuate brace configured to span a wearer's head, the brace comprising: a forehead portion anteriorly secured to a front of the user's head; a pair of arms cantileveredly connected to opposite lateral extents of the forehead portion, each of the support arms having a free end laterally spaced a distance from the head; and the device further comprising a first flexible tensioning member having a first end connected to a first of the arms, a second end connected to a second of the arms, and an intermediate portion oriented to abut against a back of the user's head.

[0013] In some embodiments, the distance is between 5.0 and 30 mm.

[0014] In some embodiments, the free end of each of the support arms is positioned posterior to a coronal plane that substantially bisects the user's head when the device is worn.

[0015] In some embodiments, the brace is subjected to a mechanical elastic strain; The amount of strain is such that the transverse gap between the free ends is reduced to less than 5% of the unloaded gap.

[0016] In some embodiments, the apparatus further comprises a guide bracket having a first rigidity pivotally attached to a first of the support arms.

[0017] In some embodiments, the first flexible tensioning member comprises a number of positioning straps.

[0018] In some embodiments, the straps comprise lateral straps and coronal straps.

[0019] In some embodiments, the first end of the first tensioning member is spaced a lateral distance from the head.

[0020] In some embodiments, the free ends are disposed at an angle of at least 185 degrees from one another as measured along the brace about the central axis of the head to which the brace is secured.

[0021] In some embodiments, a device is provided that includes headgear, the headgear comprising a rigid anterior elongated arcuate brace that spans laterally across the forehead, the brace comprising a pair of rearwardly projecting rigid support arms, and a flexible rear tensioning member having first and second opposite ends connected to the arms.

[0022] In some embodiments, each of the arms includes a rearward free end, and the tensioning member is under tension to cause lateral inward deflection of the free ends.

[0023] In some embodiments, a first one of the support arms includes a free end spaced a lateral distance from the head.

[0024] In some embodiments, the lateral distance is between 5.0 and 30 mm.

[0025] In some embodiments, the headgear further comprises a first elongated bracket having a first end movably connected to the first support arm.

[0026] In some embodiments, the first elongated bracket is hingedly connected to the first support arm.

[0027] In some embodiments, a first one of the opposing ends of the tensioning member is wound on a spool that is rotatably mounted to the bracket.

[0028] In some embodiments, a method for increasing headgear comfort is provided, the method comprising the steps of selecting headgear including a rigid, arcuate brace having a pair of substantially rigid support arms that straddle a user's head and cantilever laterally and rearwardly beyond the user's temples to form a pair of free ends; attaching a tensioning member to the free ends; applying a tension load to the tensioning member; and deflecting the free ends toward each other while avoiding contact between the arms and the head.

[0029] The original claims are incorporated herein by reference as describing features in some embodiments. [Brief explanation of the drawings]

[0030] [Figure 1] 1 is a prior art schematic perspective view of a human head and defined mutually orthogonal reference planes of the head; FIG. [Figure 2] 1 is a prior art schematic side view of headgear fitted on a human head. [Figure 3] 1 is a prior art schematic cross-sectional top view of headgear fitted on a human head. [Figure 4] FIG. 1 is a schematic perspective view of a person wearing compression-adaptive headgear according to an alternative exemplary embodiment of the present invention. [Figure 5] 1 is a prior art schematic cross-sectional top view of compression adaptive headgear. FIG. [Figure 6] 1 is a schematic cross-sectional top view of compression adaptive headgear strained by a lateral compressive load. FIG. [Figure 7] FIG. 1 is a schematic side view of a compression-adaptive headgear mounted on a human head that provides greater resistance to pitching motion due to vertical loads. [Figure 8] FIG. 1 is a schematic perspective view of a person wearing compression-adaptive headgear attached to a head and neck support device according to an alternative exemplary embodiment of the present invention. [Figure 9] FIG. 9 is a schematic cross-sectional top view of the compression-adaptive headgear of FIG. 8. [Figure 10] 1 is a flow diagram of a method of using compression-force adaptive headgear in accordance with an exemplary embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0031] References herein to top, bottom, superior, inferior, upper, lower, vertical, horizontal, lateral, lateral, posterior, anterior, proximal, distal, etc. may be used to provide an explicit frame of reference for various structures relative to other structures that are normally oriented in the drawings to which they refer. These references should not be treated as absolute when the frame of reference is changed, such as when the device is inverted, shown on its side, or disassembled.

[0032] As used herein, the term "substantially" can be used in reference to manufacturing imprecision and inaccuracies that may lead to asymmetries and other inaccuracies in the shape, dimensioning, orientation, and positioning of various structures. Furthermore, the use of "substantially" in connection with particular geometries and orientations, such as "parallel" and "perpendicular," can be provided as a guide to generally describing the function of various structures and to allow for slight deviations from precise mathematical geometric shapes and their orientations, such as cylinders, ellipses, disks, cones, etc., while adequately providing similar functionality. Those skilled in the art will readily understand the extent to which deviations from mathematically precise geometric standards are possible.

[0033] As used herein, the term "axial" is intended to refer to a direction, motion, or force acting substantially parallel to or along the axis, and is not intended to refer to rotational, radial, angular, or torsional motions or forces.

[0034] In this specification, the unit "millimeter" or "millimeters" may be abbreviated as "mm", and the unit "centimeter" or "centimeters" may be abbreviated as "cm".

[0035] This specification may refer to the use of multiple patches or layers of hook-and-vane fabric fasteners, such as VELCRO brand fasteners available from Velcro USA Inc. of Manchester, New Hampshire, in which a patch of hook-and-vane fabric fasteners of a first type (either hook or vane) can be releasably fastened to a patch of the opposite type. For example, a hook-type patch would releasably adhere to a vane-type patch or some other common loosely woven fabric. For clarity, such fasteners are referred to herein as fabric fasteners, and a patch of fabric fasteners attaches to a corresponding patch of fabric fasteners. Those skilled in the art will readily understand which type is best used for any given patch and whether matable patch types are interchangeable.

[0036] 4 and 5, headgear 40 according to an exemplary embodiment of the present invention is shown for comfortably accommodating forces applied to the headgear. Such forces may be applied by the effect of gravity on attachments 41, such as a flashlight and / or face shield.

[0037] The headgear 40 may include a rigid, arch-shaped brace 42 extending substantially parallel to the head's transverse plane TP and spanning the wearer's 10 forehead. The brace may include a rigid forehead portion 43 with a bending radius of approximately 9 cm, allowing the brace to be tightly secured to the forehead via elastic pads 60 for comfort and fit. A pair of support arm temple pieces 44a, 44b may be cantilevered from the forehead portion. In other words, the first support arm 44a may have a fixed end 45a connected to the left lateral extent 43a of the forehead portion and an opposite free end 45b extending laterally and rearward away from the head in a cantilevered manner. In practice, the free end may be positioned a lateral distance D1 from the head. For a typical brace with a bending radius of approximately 9 cm and an arc of approximately 225 degrees relative to the head's vertical central axis, a distance of approximately 5.0 to 30 mm may be appropriate.

[0038] Similarly, the second support arm 44b can have a fixed end 46a connected to the left lateral extent 43b of the forehead portion and an opposite free end 46b extending laterally and posteriorly in a cantilevered manner away from the head. In this manner, the brace can be symmetrical with respect to the sagittal plane SP of the head. It should be understood that the entire brace, including the forehead portion and both support arms, can be fabricated from a single piece of durable, rigid material, such as carbon fiber composite or stainless steel. In this manner, the transition 47 between the mid-forehead portion and the support arm can be smooth without a clear boundary between the forehead portion and the fixed end of the support arm.

[0039] The headgear 40 may also include a flexible tensioning member 50, which may be formed by an elongated flexible strap 51 extending substantially parallel to the transverse plane TP and an elongated flexible coronary band 52 extending substantially parallel to the coronal plane CP. A first end 53 of the strap may be secured to the free end 45b of the first support arm 44a, and a second end 54 may be secured to the free end 46b of the second support arm 44b. An intermediate portion 55 of the strap may be oriented to abut against the back of the user's head 10. The coronary band may extend across the top of the head substantially in the coronal plane CP and may be attached at opposite ends of the coronary band to the free ends 45b, 46b of the support arms. The length of the strap may be adjustable using an elastic material, as shown, or a substantially inelastic material, in which case various adjustable fasteners known in the art, such as snaps, buckles, or fastening grips, may be used.

[0040] The flexible tensioning member 50 can be secured to the brace 42 in several ways. The two dissimilar pieces of material can be attached using adhesive patches 56, 57 as shown. Alternatively, the pieces of material can be fastened using various commonly known fasteners, such as screws, snaps, rivets, or other connectors. Alternatively, the pieces of material can be secured by cooperating joints or other interlocking mechanisms formed in the geometry of the interfacing surfaces. Various hinged or pivoting connections can also be used. Depending on the materials used, the materials can be co-molded. For example, a polyethylene terephthalate (PET) flexible tensioning member can be injection molded onto a pre-formed carbon fiber brace. Various surface features, such as vias through the brace, can provide a more robust bond.

[0041] Attaching tensioning member 50 to free ends 45b, 46b of support arms 44a, 44b of arcuate brace 42 allows ends 53, 54 of strap 51 to be spaced a lateral distance D2 from the wearer's head 10. For a typical brace having a bending radius of approximately 9 cm and an arc of approximately 225 degrees relative to the head's vertical central axis, a distance of approximately 2.0 to 15 mm may be appropriate. This spacing ensures that the load on the tensioning member is borne by the brace and not the wearer's temples.

[0042] To further ensure that the load on the tensioning member 50 is supported by the brace 42, the brace can be dimensioned so that the free ends 45 b, 46 b of the support arms are positioned posterior to the coronal plane CP, which intersects the central axis 6 of the head. By providing that the angular separation of the free ends 45 b, 46 b of the support arms is at an angle A2 of at least 185 degrees, and more preferably at least 190 degrees, relative to the central vertical axis 6 passing through the center of gravity or volume of the head, the lateral compressive load supplied by the tensioning member can be accommodated by the brace without undue deformation. By providing that the angular separation of the fixed ends 45 a, 46 a of the support arms is at an angle A1 of at least 90 degrees, and more preferably at least 100 degrees, the support arms can be properly cantilevered laterally away from the head.

[0043] Referring now to FIG. 6, due to material limitations as well as weight and size limitations, the brace cannot be made completely rigid. Therefore, lateral compressive forces will cause the free ends of the support arms to deflect inward. However, a maximum amount of deflection is allowed that will keep the support arms spaced apart from the temples. Thus, for brace 60 having a bend radius of approximately 9 cm and an arc A3 of approximately 225 degrees, the lateral gap G1 between free ends 61, 62 will decrease by less than 5% under a lateral compressive load L of approximately 2.25 Newtons (10 pounds-force) applied to the free ends.

[0044] Figure 7 shows that a brace 70 having a bend radius of approximately 9 cm and an arc of at least 185 degrees allows the free ends 71 ​​of the support arms to extend posteriorly beyond the coronal plane CP, which intersects the central axis of the head. Tension on tensioning member 72 tends to limit any upward movement of the free ends due to the weight W of the attachment cantilevered forward from the front of the brace. In this way, the rigid, arcuate brace of the headgear provides resistance to the pitch forces described in connection with Figures 2 and 3.

[0045] 8 and 9, an alternative embodiment of headgear 160 for use in apparatus 100 to support a wearer's head 103 and neck 102 during repetitive, prolonged activities such as those encountered by assembly line workers is shown. The headgear can be adapted to provide greater comfort to the wearer by including a padded, rigid, arcuate, lateral compression-resistant brace 161 that extends laterally across the head 103, substantially parallel to the transverse plane TP. The curvature of the brace is selected so that a concave forehead portion 162 of the brace nests against the wearer's forehead, while rigid lateral support arms 163, 164 extend laterally and posteriorly away from the wearer's temples and in a cantilevered manner away from the head. Pads 166 made of a resilient material, such as fabric-covered foam rubber, can provide a more comfortable, intimate surface between the brace and the wearer's forehead. The arms provide a rigid structure to accommodate potentially uncomfortable lateral compressive forces generated by flexible adjustable lateral and coronal straps 167 and 168 and the support cables 131 described below. Each of the straps can be adjusted using a length adjustment mechanism 169, such as a spring-loaded pin that engages a discreet hole 170. The ends of the straps can be interchangeably attached to the free ends of the support arms using threaded fasteners 171.

[0046] The connector 130 can securely attach the headgear 160 to the beam 110 or other relatively fixed structure. The connector can include a flexible cable 131 with both ends secured to opposite sides of the headgear. A first end of the cable can be secured to a spindle 132 rotatably mounted on a guide bracket 133 attached to the free end 155 of the support arm 163 of the brace 161 with a swivel mount 134. The spindle can form a landing for the cable end on the headgear. The cable can be slidably connected to the connector to allow the user to move their ears in a yaw motion with little resistance.

[0047] The guide bracket 133 may include a cable guide 135 through which the cable slidably passes and abuts. The opposite end of the cable may be attached to a similar guide bracket 153 pivotally mounted by a swivel 154 to an opposite support arm 164 of a brace 161 on the opposite side of the headgear, with or without an adjustable spindle 152 that forms another landing for the cable on the headgear. An intermediate portion of the cable may be slidably secured to the housing 140 of the connector 130. The distance between the headgear and a relatively fixed structure, such as the beam 110, may be adjusted by adjusting the amount of cable wrapped around one or both of the spindles.

[0048] When supporting the head, the cable 131 of the head and neck support device 100 is under tension, which exerts a lateral compressive force on the headgear in addition to the lateral compressive force exerted by the headgear straps 167, 168. The combination of the straps and cable thus forms a tensioning element on the brace. The compressive force is resisted by the rigid, arcuate brace 161 in a manner that prevents the force from being borne by the wearer's temples. This is accomplished by ensuring that the force is applied to the brace near the free ends 155, 156 of the support arms 163, 164. Therefore, the location of the guide bracket swivel mounts 134, 154 can be positioned posterior to the coronal plane CP, which intersects with the head's central axis 106. By ensuring that the angular separation of the swivel mounts is at an angle A4 of at least 185 degrees, more preferably at least 190 degrees, relative to the central axis 106, the lateral compressive load provided by the cable and strap can be accommodated by the brace without excessive deformation.

[0049] Referring now to Figure 10, an exemplary embodiment of a method 200 for increasing comfort in headgear capable of undergoing lateral compressive loads will be described. The method can include selecting 201 a headgear support device including a rigid, arcuate brace having a pair of substantially rigid support arms cantilevered across a user's head and extending laterally and rearward beyond the user's temples. Tensioning members can be attached at either end to the free ends of the support arms 202. When a tensile load is applied to the tensioning members 203, the arms tend to deflect 204 toward the wearer's head. This deflection is resisted 205 by the stiffness of the brace.

[0050] The above-described embodiments of the brace can provide bending stiffness as a function of distance from the front end of the brace, which can be determined according to the brace geometry, the brace material properties, such as fiber orientation in embodiments using fiber composite materials in various regions of the brace, and the settings of adjustable features, such as the tensioning cables, described above.

[0051] In this way, the device can provide greater comfort when the headgear is used in a head and neck support system to reduce loads on the back, neck, spine and head during work and job-related postures and body positioning.

[0052] In some embodiments, the connector that attaches the brace to the arm can have a quick connect mechanism that allows for easy engagement and disengagement to interchange braces and pads with different mechanical or aesthetic properties.

[0053] In some embodiments, the bending stiffness of the brace can vary along the length of the brace, making it infinitely adjustable for each individual user. In some embodiments, the brace can include one or more members with tapered geometries that can bridge the edges together. In some embodiments, the brace can include one or more members made of composite construction and designed to act as a lightweight counterspring against the force of the cables.

[0054] While preferred embodiments of the invention have been described, modifications may be made and other embodiments may be devised without departing from the spirit of the invention and the scope of the appended claims.

Claims

1. A device worn on a user's head, The device comprises: a rigid, arcuate brace configured to span the wearer's head; a first flexible tensioning member; The brace is a forehead portion secured forward to a front portion of the user's head; a pair of support arms cantileveredly connected to opposite lateral extents of the forehead portion; each of the support arms having a free end laterally spaced a distance from the head; The first flexible tensioning member comprises: a first end connected to a first one of the support arms; a second end connected to a second one of the support arms; and a middle portion oriented to rest against the back of the user's head.

2. The device of claim 1 , wherein the distance is between 5.0 and 30 mm.

3. 10. The device of claim 1, wherein the free end of each of the support arms is positioned posterior to a coronal plane that substantially bisects the user's head when the device is worn.

4. The brace is subjected to mechanical elastic strain; The apparatus of claim 1 , wherein the amount of strain causes a reduction in the lateral gap between the free ends to less than 5% of the unloaded gap.

5. The apparatus of claim 1 further comprising a first rigid guide bracket pivotally mounted to a first of the support arms.

7. The device of claim 1 , wherein the first flexible tensioning member comprises a number of positioning straps.

8. The device of claim 7 , wherein the straps comprise lateral straps and coronal straps.

9. The device of claim 1 , wherein the first end of the first flexible tensioning member is spaced a lateral distance from the head.

10. 10. The device of claim 9, wherein the free ends are disposed at an angle of at least 185 degrees from one another as measured along the brace about a central axis of the head to which the brace is secured.

11. 1. A device comprising headgear, The headgear comprises: A rigid, forward, elongated, bow-shaped brace extending laterally across the forehead; a flexible rear tensioning member having first and second opposing ends; the brace includes a pair of rearwardly projecting rigid support arms; The opposite ends are connected to the support arms.

12. each of the support arms having a rear free end; The device of claim 11 , wherein the rear tensioning member is under tension to cause lateral inward deflection of the free end.

13. 12. The device of claim 11, wherein a first one of the support arms includes a free end spaced a lateral distance from the head.

14. The apparatus of claim 13, wherein the lateral distance is between 5.0 and 30 mm.

15. The apparatus of claim 11 , wherein the headgear further comprises a first elongated bracket having a first end movably connected to the first support arm.

16. The apparatus of claim 15 , wherein the first elongated bracket is hingedly connected to the first support arm.

17. 12. The apparatus of claim 11, wherein a first one of the opposing ends of the rear tensioning member is wound on a spool rotatably mounted to the bracket.

18. 1. A method for increasing headgear comfort, comprising: The method comprises: selecting headgear including a rigid, arcuate brace having a pair of substantially rigid support arms that straddle a user's head and cantilever laterally and rearwardly beyond the user's temples to form a pair of free ends; attaching a tensioning member to the free end; applying a tensile load to the tensioning member; and flexing the free ends toward each other while avoiding contact between the arms and the head.

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