Support Structure for Headgear With Integrated Ventilation and Anchoring

Abstract

A headgear support structure for use with various types of headgear includes a rim defining a perimeter with a front edge, a rear edge, and opposing side edges; a wall extending between the edges of the rim, having an exterior surface and an interior surface; a plurality of ridges formed on the exterior surface defining grooves between them; a plurality of ventilation openings extending through the wall; and a plurality of angled pins projecting from the interior surface to engage with a wearer's hair. The structure is configured to maintain hair volume, provide ventilation for scalp health, and create a secure foundation for headgear through multi-directional friction. The support structure may be formed as a single integrated unit using additive layer manufacturing, creating a microtextured surface that enhances grip on both hair and fabrics. The structure is configurable for various headgear types including religious coverings, wigs, helmets, and fashion accessories.

1 . A headgear support structure, comprising:
 a rim defining a perimeter of the support structure, the rim including a front edge, a rear edge, and opposing side edges;   a wall extending between the edges of the rim, the wall having an exterior surface and an interior surface;   a plurality of ridges formed on the exterior surface of the wall, the ridges defining a series of grooves therebetween;   a plurality of ventilation openings extending through the wall from the interior surface to the exterior surface; and   a plurality of pins extending from the interior surface, each pin having a pin base connected to the interior surface and angled relative to the interior surface.   
     
     
         2 . The headgear support structure of  claim 1 , wherein the wall is curved in multiple planes to conform to a curvature of a wearer's head, such that the interior surface is concavely curved and the exterior surface is convexly curved. 
     
     
         3 . The headgear support structure of  claim 1 , wherein the pins are arranged in a plurality of pin rows, including front-to-back pin rows extending generally from the front edge toward the rear edge and side pin rows positioned along opposing side sections of the support structure. 
     
     
         4 . The headgear support structure of  claim 3 , wherein the front-to-back pin rows comprise ten rows arranged in parallel pairs, and wherein the side pin rows comprise four rows on each side of the support structure. 
     
     
         5 . The headgear support structure of  claim 1 , wherein the support structure is formed as a single integrated unit using an additive layer manufacturing process. 
     
     
         6 . The headgear support structure of  claim 5 , wherein the additive layer manufacturing process creates a microtextured surface in the 20-70 micron range that enhances grip on both hair and fabric. 
     
     
         7 . The headgear support structure of  claim 1 , wherein the pins are angled at approximately 65 degrees relative to the interior surface. 
     
     
         8 . The headgear support structure of  claim 1 , wherein the support structure is made from a material selected from the group consisting of nylon and thermoplastic polyurethane (TPU). 
     
     
         9 . The headgear support structure of  claim 1 , wherein:
 the width of each groove between adjacent ridges is approximately 1.4 mm;   the width of each ridge is approximately 1.0 mm;   the height of each ridge is approximately 0.7 mm;   the length of each ventilation opening is approximately 3.5 mm;   the length of wall between adjacent ventilation openings is approximately 2.4 mm;   the wall thickness between the interior surface and the exterior surface is approximately 0.8 mm; and   the total distance from the interior surface to a peak of each ridge is approximately 1.5 mm.   
     
     
         10 . The headgear support structure of  claim 1 , wherein the ridges are arranged in an arc pattern, with each ridge extending in an arc that originates at the rear edge or a rear portion of a side edge, intersects a bisecting plane of the support structure, and curves back toward the rear edge or a rear portion of the opposite side edge. 
     
     
         11 . A support structure for use with headgear, comprising:
 a rim having a front edge configured to be positioned above a wearer's hairline, a rear edge, and opposing side edges;   a wall extending between the edges of the rim and having an exterior surface and an interior surface;   an array of ridges projecting from the exterior surface;   a plurality of ventilation openings formed in the wall; and   a plurality of angled pins projecting from the interior surface, each pin configured to engage with a wearer's hair to secure the support structure to the wearer's head.   
     
     
         12 . The support structure of  claim 11 , wherein the front edge has an undulating profile forming concave segments at opposite sides of a bisecting plane and a convex segment that intersects the bisecting plane to form a front edge apex. 
     
     
         13 . The support structure of  claim 12 , wherein the rear edge has an undulating profile with concave segments at opposite sides of the bisecting plane, a convex segment intersecting the bisecting plane to form a rear edge apex, and angular transitions that form a rearward-sweeping profile. 
     
     
         14 . The support structure of  claim 13 , wherein each concave segment of the rear edge transitions through an angular transition into a rearward-sweeping segment that extends to a corresponding side edge. 
     
     
         15 . The support structure of  claim 11 , wherein the support structure comprises a center section configured to extend across a mid-scalp region of the wearer's head and opposing side sections configured to be positioned proximate the wearer's ears and rearward of the wearer's temples. 
     
     
         16 . A method of manufacturing a headgear support structure, comprising:
 forming, via an additive layer manufacturing process, a support structure having:
 a curved wall with an interior surface and an exterior surface; 
 a plurality of ridges protruding from the exterior surface; 
 a plurality of ventilation openings extending through the wall; and 
 a plurality of pins extending from the interior surface at an angle of approximately 65 degrees relative to the interior surface. 
   
     
     
         17 . The method of  claim 16 , wherein the additive layer manufacturing process comprises selective laser sintering (SLS) or Multi Jet Fusion (MJF). 
     
     
         18 . The method of  claim 16 , wherein the forming step creates a microtextured surface in the 20-70 micron range. 
     
     
         19 . The method of  claim 16 , wherein the headgear comprises a hijab or scarf. 
     
     
         20 . The method of  claim 16 , wherein the forming step comprises forming the support structure from one of nylon and thermoplastic polyurethane (TPU).