Protective Headgear

Abstract

A protective device for a head of an individual person. The protective device forms a cap that includes a flexible headpiece and a segmented outer protective shell disposed about the flexible headpiece for distributing an impact load. The device covers and protects the front, top, sides and back of the head from impact injuries and rebound effects of high speed objects as seen for example, a baseball or softball moving at a speed of up to about 125 mph.

1 - 61 . (canceled) 
     
     
         62 . A protective cap comprising:
 a deformable headpiece of energy-absorbing, compression set resistant material defining an inner surface and an outer surface, the inner surface being concave with a variable radius of curvature to define a crown profile and hat size;   a protective shell disposed about the outer surface of the headpiece, the shell including a plurality of panels, each of the plurality of panels having a durometer hardness greater than that of the headpiece energy absorbing material; and   an outer baseball-style cap housing the headpiece and the outer protective shell.   
     
     
         63 . The protective cap of  claim 62 , wherein the outer surface and inner surface of the headpiece define a thickness therebetween ranging from ¼ inch to ⅜ inch and each of the plurality of panels have a thickness ranging from 1/10 inch to ⅛ inch. 
     
     
         64 . The protective cap of  claim 62 , wherein the baseball-style cap includes a seal folded over the base of the headpiece to secure the headpiece and the protective shell within the outer baseball-style cap. 
     
     
         65 . The protective cap of  claim 62 , wherein the outer baseball-style cap defines a hat size that is ½ to one size larger than the headpiece hat size. 
     
     
         66 . The protective cap of  claim 62 , wherein the crown profile is a low crown profile. 
     
     
         67 . The protective cap of  claim 62 , wherein a frontal region of the headpiece defines a first portion of the crown profile having a first spherical radius of curvature, and a back region of the headpiece defines as second portion of the crown profile having a second spherical radius of curvature different than the first spherical radius of curvature. 
     
     
         68 . The protective cap of  claim 62 , wherein the plurality of panels are spaced apart to define a seam width therebetween ranging between 0.5 mm-3 mm. 
     
     
         69 . The protective cap of  claim 62 , wherein the plurality of panels include hexagonal shaped panels and pentagonal shaped panels to define a truncated icosahedron. 
     
     
         70 . A protective cap comprising:
 a headpiece of energy-absorbing foam material defining a base, an inner surface and an outer surface, the inner surface being concave with a variable radius of curvature to define a crown profile, the base circumscribing the crown profile to define an expandable circumference covering a plurality of hat sizes;   a protective shell disposed about the outer surface of the headpiece for distributing the impact load, the shell including a plurality of panels, each of the plurality of panels having a durometer hardness greater than that of the headpiece energy absorbing material; and   wherein the headpiece and protective shell are configured for housing in an outer baseball-style cap defining a hat size to house the headpiece and the outer protective shell over the plurality of hat sizes of the headpiece.   
     
     
         71 . The protective cap of  claim 70 , wherein the outer surface and inner surface of the headpiece define a thickness therebetween ranging from ¼ inch to ⅜ inch and each of the plurality of panels have a thickness ranging from 1/10 inch to ⅛ inch. 
     
     
         72 . The protective cap of  claim 70 , wherein the plurality of panels are spaced apart to define a seam width therebetween ranging between 0.5 mm-3 mm. 
     
     
         73 . The protective cap of  claim 70 , wherein the plurality of panels are spaced apart to define a seam, the cap further comprising a bridge segment connecting two panels and extending over the seam. 
     
     
         74 . The protective cap of  claim 70 , wherein the plurality of panels include hexagonal shaped panels and pentagonal shaped panels to define a truncated icosahedron. 
     
     
         75 . A protective cap comprising:
 an outer baseball-style cap;   an inner headpiece of deformable, energy-absorbing material defining a crown profile and a base circumscribed about the crown profile; and   a protective shell disposed between the outer baseball-style cap and the inner headpiece to distribute energy over the inner headpiece, the shell including a plurality of panels having a durometer hardness greater than that of the headpiece energy absorbing material, the plurality of panels being joined to one another such that the plurality of panels move with respect to one another.   
     
     
         76 . The protective cap of  claim 75 , wherein the protective shell moves independent of the inner headpiece. 
     
     
         77 . The protective cap of  claim 75 , wherein the protective shell is affixed to the inner headpiece. 
     
     
         78 . The protective cap of  claim 75 , wherein the plurality of panels are joined to one another by interconnected seams. 
     
     
         79 . The protective cap of  claim 75 , wherein the inner headpiece defines one of a semi-ovoid shape or a hemispherical shape. 
     
     
         80 . The protective cap of  claim 75 , wherein the inner headpiece defines a thickness ranging from ¼ inch to ⅜ inch and each of the plurality of panels have a thickness ranging from 1/10 inch to ⅛ inch. 
     
     
         81 . The protective cap of  claim 75 , wherein the plurality of panels include hexagonal shaped panels and pentagonal shaped panels to define a truncated icosahedron.